KR20110111037A - Manufacturing method of brightness enhancement film - Google Patents

Abstract

The present invention provides a method for manufacturing a luminance-enhanced film which improves the phenomenon of cow hair by preventing the birefringent island-in-the-sea yarn trimming.
The luminance-enhanced film including the birefringent island-in-the-sea yarn manufactured by the manufacturing method of the present invention does not generate entanglement between the birefringent island-in-the-sea yarns (mono yarn), so that no fiber band is generated and visibility is improved. In addition, even if the birefringent island-in-the-sea yarns are not subjected to a separate weaving process or weed together, only a few strands of coarse fibers are spliced, so that some fibers do not appear to be cut off, which can block the occurrence of cows.

Description

MANUFACTURING METHOD OF BRIGHTNESS ENHANCEMENT FILM

The present invention relates to a method for manufacturing a luminance-enhanced film, and more particularly, to a method for manufacturing a luminance-enhanced film which improves the phenomenon of cows by preventing the birefringent island-in-the-sea yarn trimming.

Flat panel display technology is mainly made up of liquid crystal display (LCD), projection display, and plasma display (PDP), which have already secured market in TV, and related technologies such as field emission display (FED) and electroluminescent display (ELD) With the improvement of the market, it is expected to occupy the field according to each characteristic. LC displays are currently expanding their range of use, including notebooks, personal computer monitors, liquid crystal TVs, automobiles, and airplanes, accounting for about 80% of the flat panel market. have.

Conventional LC displays place liquid crystals and electrode matrices between a pair of light absorbing optical films. In an LC display, the liquid crystal portion has an optical state that is changed accordingly by moving the liquid crystal portion by an electric field generated by applying a voltage to two electrodes. This process displays an image of a 'pixel' carrying information using polarization in a specific direction. For this reason, LC displays include front and back optical films that induce polarization.

  The luminance-enhanced film of such an LC display is not necessarily a high utilization efficiency of light emitted from the backlight. This is because at least 50% of the light emitted from the backlight is absorbed by the rear optical film. Thus, in order to increase the utilization efficiency of the backlight light in the brightness enhancement film, the brightness enhancement film is provided between the optical cavity and the liquid crystal assembly.

  1A is a view showing the optical principle of a conventional brightness enhancement film. Specifically, P-polarized light from the optical cavity to the liquid crystal assembly passes through the luminance-enhanced film to be transmitted to the liquid crystal assembly, and S-polarized light is reflected from the luminance-enhanced film to the optical cavity and then polarized light on the diffuse reflection surface of the optical cavity. The direction is reflected in a randomized state and then transmitted to the luminance-enhanced film so that S-polarized light is converted into P-polarized light that can pass through the polarizer of the liquid crystal assembly, and then passed through the luminance-enhanced film and then transferred to the liquid crystal assembly.

The selective reflection of S-polarized light and the transmission of P-polarized light with respect to the incident light of the luminance-enhanced film have a refractive index between the optical layers in a state where an optical layer on a plate having anisotropic refractive index and an optical layer on a plate having an isotropic refractive index are alternately stacked. It is made by the optical thickness setting of each optical layer and the refractive index change of the optical layer according to the difference and the stretching process of the stacked optical layers.

  That is, the light incident on the luminance-enhanced film repeats the reflection of S-polarized light and the transmission of P-polarized light while passing through each optical layer, and eventually only the P-polarized light of the incident polarization is transmitted to the liquid crystal assembly. On the other hand, the reflected S-polarized light is reflected in a state in which the polarization state is randomized at the diffuse reflection surface of the optical cavity and is transmitted to the luminance-enhanced film as described above. As a result, power loss can be reduced together with the loss of light generated from the light source.

  However, such a conventional brightness enhancement film is laminated with anisotropic optical layer and anisotropic optical layer on a plate having different refractive indices and stretched to obtain optical thickness and refractive index between each optical layer that can be optimized for selective reflection and transmission of incident polarization. Since it is manufactured to have, there is a problem that the manufacturing process of the luminance-enhanced film is complicated. In particular, since each optical layer of the luminance-enhanced film has a flat plate structure, it is necessary to separate P-polarized light and S-polarized light in response to a wide range of incident angles of incident polarization, so that the number of optical layers is excessively increased and the production cost is exponentially increased. There was a growing problem. In addition, due to the structure in which the number of laminated layers of the optical layer is excessively formed, there is a problem that the optical performance decrease due to light loss.

Accordingly, it has been found that the luminance-enhanced film including the birefringent island-in-the-sea yarn inside the substrate is advantageous in overcoming the above-described problem. Specifically, when the birefringent island-in-the-sea yarns were used, it was confirmed that the effects of light modulation efficiency and luminance improvement were remarkably improved compared with the case of using the conventional birefringent fibers. The seam portion constituting the island-in-the-sea yarn has anisotropy, and the sea portion partitioning the seam portion has isotropy. In this case, not only the interface between the island-in-the-sea yarn and the base material, but also the interface between the islands and sea portions of the island-in-the-sea yarn has a birefringent interface, so that a birefringent interface is generated only at the interface between the base material and the birefringent fibers. Compared to the fiber, the light modulation effect is significantly increased, so that it can be applied to the actual industrial site by replacing the laminated luminance-enhanced film. Therefore, the use of birefringent island-in-the-sea yarn is superior to the use of conventional birefringent fibers, and the efficiency of brightness enhancement is excellent. What can form an interface is that the brightness enhancement efficiency can be remarkably improved as compared with the case where it is not.

On the other hand, in order to maximize the light modulation efficiency, the larger the area of the birefringent interface in the birefringent islands, the greater the advantage, for this purpose, the number of islands in the birefringent islands should be larger. However, the conventional islands and islands are arranged concentrically around a single spinning core inside the islands, and the structure of such a cross section is fine when the number of the islands is small, but when the number of islands increases (about 300 or more), in the case of the island portion adjacent to the spinning core formed in the center of the island, the density becomes large, and the phenomenon of agglomeration (conjugation phenomenon) occurs in the portion of the coating located around the spinning core during the spinning process. More specifically, FIG. 1B is a cross-sectional view of the conventional islands of the islands (FIG. 331), wherein the islands 12 are arranged concentrically around a single radiation core 11 within the islands. The cross section occupies 30 to 70%. This cross-sectional structure is not abnormal when the number of islands is small, but when the number of islands is increased (about 300 or more) or when the ratio of the cross-sectional area of the islands of the islands is increased, the radiation core formed at the center of the islands In the case of the dojo portion adjacent to (11), the density becomes large, and the phenomenon of agglomeration between the dove portions located around the radiating core occurs in the spinning process. In other words, as the number of islands of islands in the sea island increases, there is a side effect (conjugation phenomenon) in which the island parts of the islands of the islands agglomerate to form a mass.

Therefore, the birefringent island-in-the-sea yarn having a cross-sectional shape of a conventional island-in-the-sea yarn has a problem in that the birefringence interface is reduced due to the degree of conduction.

Furthermore, since the number of birefringent islands in the conventional luminance-enhanced film is only 36 to 300, the number of the portion is 10 to 30 ㎛ in diameter and the number of the portion is 100 for practical use in order to increase the light modulation efficiency. The birefringent island yarn mono yarns of ~ 300 were used in the form of twisted 7 ~ 144 strands (40de / 12fila ~ 500de / 144fila). As a result, the birefringent interface was increased, but the optical modulation efficiency was improved, but entanglement occurred between the monofilamented mono yarns. Thus, the fibrous band was generated when the birefringent sea island yarns were placed on the luminance-enhanced film. In addition, when several tens of hundreds of mono yarns are drawn together and stretched, some strands of the fibers are broken (broken) to occur, resulting in the phenomenon of cattle. As a result, the direction of the fiber is changed in the section where the trimming occurs, so that the reverse polarization effect is shown, which not only lowers the light modulation efficiency but also acts as a drawback when the luminance-enhanced film is used in the liquid crystal display. In addition, when the occurrence of the wool caused a problem that the weaving is poor due to the impeding the progress of the weft due to the poor opening movement during the weaving (in the fabric manufacturing) of the birefringent sea island yarns, the problem of reducing the weaving workability occurred.

The present invention has been made to solve the above-described problems, the first problem to be solved by the present invention is to provide a method for producing a luminance-enhanced film that does not generate a fiber band by preventing entanglement between birefringent islands.

A second object of the present invention is to provide a method for manufacturing a brightness-enhanced film that prevents birefringence island thread thread trimming so that no phenomenon occurs.

The present invention, in order to achieve the first object, (1) weaving or weaving either one of the birefringent islands and yarns in which the A value of the following relation 1 is 500 or more and weaving the other fiber; (2) it provides a method for producing a brightness-enhanced film comprising placing the woven fabric between the substrate and performing a lamination process.

[Relationship 1]

A = number of islands in mono yarn / number of mono yarns forming one plywood

According to a preferred embodiment of the present invention, the A value may be 1000 or more, preferably 5000 or more, more preferably 10000 or more, and more preferably 20000 or more.

According to another preferred embodiment of the present invention, the number of birefringent islands in the yarn may be 1000 or more, preferably 5000 or more, more preferably 10000 or more, most preferably May be more than 20000.

According to another preferred embodiment of the present invention, the birefringent island-in-the-sea yarn may have the number of islands of mono yarn more than 10,000.

According to another preferred embodiment of the present invention, the number of birefringent island-in-the-sea yarns may be 20000 or more.

According to a preferred embodiment of the present invention, the diameter of the monofilament of the birefringent island-in-the-sea yarn may be 30 μm or more, and more preferably 40 to 100 μm.

According to another preferred embodiment of the present invention, the birefringent islands may be 15 to 500 denier / 1 to 6 strands.

According to another preferred embodiment of the present invention, the birefringent island-in-the-sea yarn may be a mono yarn or two to six strands plyed together.

According to another preferred embodiment of the present invention, the birefringent island-in-the-sea yarn is woven in the form of a fabric, one of the weft or warp of the fabric is a birefringent island-in-the-sea yarn and the other is a fiber, The melting start temperature of the portion may be higher than the melting temperature of the fiber.

According to another preferred embodiment of the present invention, a birefringent interface may be formed at the boundary between the island portion and the sea portion of the birefringent islands.

According to a preferred embodiment of the present invention, the fiber may be an isotropic fiber having optical properties.

According to another preferred embodiment of the present invention, the fiber may be any one or more fibers selected from the group consisting of polymer fibers, natural fibers and inorganic fibers.

According to another preferred embodiment of the present invention, the melting start temperature of the island portion of the birefringent island-in-the-sea yarn may be higher than the melting temperature of the sea portion, and more preferably, the melting start temperature of the island portion of the birefringent island-in-the-sea yarn is dissected. It may be at least 30 ° C. above the melting temperature of the powder.

According to another preferred embodiment of the present invention, the melting start temperature of the island portion of the birefringent islands of the seams may be 30 ℃ or more higher than the melting temperature of the fiber.

According to another preferred embodiment of the present invention, the lamination process may be performed at a temperature condition that satisfies the following relation (2).

[Relationship 2]

Melting temperature of the fiber (℃) <Lamination temperature (℃) <Melting start temperature of the coating part (℃)

According to another preferred embodiment of the present invention, the melting start temperature of the island portion of the birefringent island-in-the-sea yarn may be higher than the melting temperature of the sea portion, and more preferably, the melting start temperature of the island portion of the birefringent island-in-the-sea yarn is dissected. It may be at least 30 ° C. above the melting temperature of the powder.

According to another preferred embodiment of the present invention, the melting start temperature of the island portion of the birefringent islands of the seams may be 30 ℃ or more higher than the melting temperature of the fiber.

According to another preferred embodiment of the present invention, part or all of the sea portion of the birefringent island-in-the-sea yarn may be molten.

 According to another preferred embodiment of the present invention, the sea portion of the fiber and the birefringent island-in-the-sea yarn may be the same component.

According to another preferred embodiment of the present invention, the optical properties of the island portion may be birefringent, and the optical properties of the sea portion may be isotropic.

According to another preferred embodiment of the present invention, the refractive index of the substrate and the birefringent island-in-the-sea yarn has a difference in refractive index of 0.05 or less in two axial directions, the difference in refractive index in the other one axial direction may be 0.1 or more Preferably, the base material is birefringent when the refractive index in the x-axis direction of the substrate is nX1, the refractive index of the y-axis direction is nY1, the refractive index of the z-axis direction is nZ1, and the refractive indices of the birefringent island-in-the-sea yarns are nX2, nY2, and nZ2. At least one of the X, Y, and Z-axis refractive indices of the island-in-the-sea yarn may coincide, and more preferably nX2> nY2 = nZ2.

According to another preferred embodiment of the present invention, the refractive index of the sea portion and the island portion of the birefringent island-in-the-sea yarn has a difference in refractive index of 0.05 or less in two axial directions, and a difference in refractive index of one remaining axial direction in 0.1 The refractive index in the x-axis direction in the longitudinal direction of the island portion of the birefringent island-in-the-sea yarn is nX3, the refractive index in the y-axis direction is nY3 and the refractive index in the z-axis direction is nZ3, and the x-axis direction of the sea portion When the refractive index is nX4, the refractive index in the y-axis direction is nY4 and the refractive index in the z-axis direction is nZ4, at least one of the X, Y, and Z-axis refractive indices of the substrate and the birefringent island-in-the-sea yarn may coincide, more preferably, The absolute value of the difference between the refractive indices of nX3 and nX4 may be 0.1 or more.

According to another preferred embodiment of the present invention, the refractive index of the sea portion of the birefringent island-in-the-sea yarn may be the same as the refractive index of the substrate.

According to another preferred embodiment of the present invention, the fabric may be woven into an asymmetrical tissue such that the birefringent islands are exposed to the surface more than the fiber.

The terms used herein are briefly described.

'Fiber has birefringence' means that when light is irradiated on a fiber having a different refractive index according to the direction, the light incident on the polymer is refracted by two lights having different directions.

'Isotropic' means that when light passes through an object, the refractive index is constant regardless of the direction.

'Anisotropy' means that the optical properties of an object are different depending on the direction of light. Anisotropic objects have birefringence and correspond to isotropy.

'Light modulation' means that the irradiated light is reflected, refracted, scattered, or the intensity of the light, the period of the wave, or the nature of the light is changed.

'Monosa' refers to a type of fiber that is wound around a single thread without being used as a single thread by twisting several strands of thread. .

'Pumped' means the type of fiber used by winding two or more threads simultaneously through twisting, interlacing, etc. so that two or more mono yarns behave like one thread. It is not included in the plywood of the present invention that the fibers passing through the capillary or island component supply unit are combined before discharge. Therefore, it is the mono yarn itself that forms a birefringent island-in-the-sea yarn before spinning after the microfibers are each microfiber in the birefringent island-in-the-sea yarn and the microfibers pass through different nozzles.

"Fur phenomenon" refers to a defect that appears by cutting some of the fibers of the number of fibers constituting the plywood.

The term 'spinning core' refers to the case where the island part is arranged by grouping a certain point inside the island in the cross section (the center of the yarn) when cutting the island in the longitudinal direction. In the case of compartments).

The term 'radiation reference core' refers to a radiation core which is a center when a plurality of radiation cores exist and the other radiation cores are arranged around one radiation core, and the 'radiation peripheral core' refers to one radiation core. It means the remaining spinning core to be arranged.

'Doing parts are grouped and arranged' means that the island parts of the islands and islands are partitioned and aligned with a certain shape around one spinning core. For example, when there are two spinning cores inside the islands Since the island-in-the-sea yarn is arranged in a uniform shape around each spinning core, the island part is divided into two groups within the island-in-the-sea yarn.

The 'melting start temperature' refers to the temperature at which the melting of a polymer begins, and the 'melting temperature' refers to the temperature at which melting occurs most rapidly. Therefore, when the melting temperature of a polymer is observed by DSC, if the end point of the endothermic peak due to melting is the melting start temperature, the temperature corresponding to the vertex of the endothermic peak is the melting temperature.

Since the luminance-enhanced film produced by the manufacturing method of the present invention does not generate entanglement between birefringent islands (monosa), fiber bands do not occur and visibility is improved. In addition, even when using bi-refractive seaweed yarns in the form of mono yarns without going through a separate weaving process, only a few strands of coarse fibers are spliced together, so that some fibers are not trimmed in the spinning or stretching process, resulting in a cow's phenomenon. Can be blocked. As a result, since the reverse polarization effect does not occur, not only the optical modulation efficiency can be maintained but also no defect occurs in the luminance-enhanced film, so that the appearance characteristics of the luminance-enhanced film can be dramatically improved. In addition, the weaving process can be improved because the weaving process does not occur by interfering with the weft due to poor opening movement during the weaving process.

1A is a schematic diagram illustrating the principle of a conventional brightness enhancing film.
1B is a cross-sectional photograph of a conventional birefringent island-in-the-sea yarn.
Figure 2 is a cross-sectional view of the injection portion of the spinneret for producing sea islands according to an embodiment of the present invention.
Figure 3 is a cross-sectional view of the portion of the detention part of the spinneret for producing sea island yarn according to an embodiment of the present invention.
4 is a cross-sectional view of a lower plate of the spinneret for manufacturing sea islands according to the related art.
5 is a cross-sectional photograph of a conventional birefringent island-in-the-sea yarn.
6 is a SEM (25x) photograph of a fabric including a conventional birefringent island-in-the-sea yarn.
7 is a SEM (40 times) photograph of a fabric including a conventional birefringent island-in-the-sea yarn.
8 is a cross-sectional view of the lower holding plate of the spinneret for producing sea island yarn according to an embodiment of the present invention.
9 is a cross-sectional photograph of a birefringent island-in-the-sea yarn according to a preferred embodiment of the present invention.
10 is a SEM (30 times) photograph of a fabric including a birefringent island-in-the-sea yarn according to a preferred embodiment of the present invention.
FIG. 11 is a SEM (30 times) photograph of a fabric including a birefringent island-in-the-sea yarn according to a preferred embodiment of the present invention.
12 is a cross-sectional view of the detention part partial plate of the spinneret for producing island-in-the-sea yarn according to an embodiment of the present invention.
Figure 13 is a cross-sectional view of the lower plate of the spinneret for sea island yarn manufacturing according to an embodiment of the present invention.
14 is a cross-sectional SEM photograph of a birefringent island-in-the-sea yarn according to a preferred embodiment of the present invention.
15 is a SEM photograph of a fabric including a birefringent island-in-the-sea yarn in accordance with a preferred embodiment of the present invention.

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

As described above, when the birefringent island-in-the-sea yarn disposed in the conventional luminance-enhanced film has a number of island portions 100 to 300, a dopant phenomenon (FIG. 1) occurs. In addition, because the number of parts is small, in order to improve the light modulation efficiency for actual commercial use, the diameter is 10 to 30㎛ 7 to 144 birefringent island-in-the-sea yarns (mono yarns) having 36 to 300 islands were used. As a result, the birefringent interface was increased and the light modulation efficiency was improved, but dozens of fibers were spliced, resulting in entanglement (twisting) between mono yarns. . In addition, when several tens of hundreds of mono yarns are drawn together and stretched, some strands of the fibers are broken (broken) to occur, resulting in the phenomenon of cattle. As a result, the direction of the fiber is changed in the section where the trimming occurs, so the reverse polarization effect is shown, which not only lowers the light modulation efficiency but also acts as a defect of the luminance-enhanced film. In addition, when the occurrence of the wool occurred when the birefringent seaweed yarn weaving (fabric manufacturing) changed the weaving machine and the thread cut when passing the heald (Radius Heald) caused a problem of reducing the weaving workability.

Accordingly, the present inventors disclose a spinneret for manufacturing sea island yarn of Korean Patent Application No. 2009-12138. Specifically, FIG. 2 is a cross-sectional view of the spinneret and includes a polymer injecting part 20 capable of injecting island and sea component polymers. FIG. 3 shows the detentional partial plate 30 included in the spinneret, and a plurality of polymer injection portions 31 are formed to radiate a plurality of birefringent islands. Each lower portion of the lower plate is formed so that the ejection openings 41, 42, and 43 corresponding to each of the polymer injection portions 31 formed in the deformed partial plate 30 are formed separately. By manufacturing (FIG. 4), a birefringent island-in-the-sea yarn (mono yarn, FIG. 5) having a number of island portions 1016 was formed therein. That is, one group island-in-the-sea yarn (FIG. 5) is manufactured in one polymer injection unit as shown in FIG. In other words, the detentional partial distribution plate of FIG. 3 may have 2 to 20 polymer injection portions arranged in series or in parallel. For example, 12 polymer injection portions of FIG. If it is formed to manufacture a lower spinneret plate (FIG. 4) having twelve individual discharge holes (41, 42, 43) corresponding to each of the polymer injection portion formed in the above-mentioned partial upper plate and to produce a total spinneret . Through this, it is possible to radiate 12 strands of birefringent islands in FIG. 5 (the number of the monoliths of the mono yarns and the diameter of the mono yarns of 19 μm) of 12 yarns, which in turn can emit 12 mono yarns through a single spinneret. .

However, even in the case of the birefringent island-in-the-sea yarn (monosa yarn) of FIG. 5, since the monomodal yarn (diameter: 19 micrometers) itself has low light modulation efficiency, it is actually 40 de (denier) / 12 fila (strand), Plywood at 80/24 (de / fila), weaving it with a weft or warp, and weaving it into a fabric and placing it inside the luminance-enhanced film. Specifically, FIG. 6 and FIG. 7 are woven fabrics 60 woven by weaving the birefringent island-in-the-sea yarn (mono yarn) of FIG. 5 and weft or warp yarns, and the fabric 60 is a birefringent island-in-the-sea yarn 61 as a warp yarn. ) Weave strands (monosa) at 80/24 (de / fila) and weaving isotropic fibers 62 as weft yarns to weave the fabric. As a result, the light modulation efficiency was improved, but the diameter of the mono yarn was small and the number of strands was increased, and some mono yarns showed trimming (A, B, and C of FIG. 6), resulting in the occurrence of blemishes and defects in the luminance-enhanced film. It became.

Thus, in the present invention, in order to achieve the first object, (1) weaving or weaving any one of the steps of weaving a woven fabric is a birefringent islands and the other fiber is A value of the relation 1 below 500; (2) solved the above problems by providing a method of manufacturing a brightness-enhanced film comprising the step of placing the woven fabric between the substrate and performing a lamination process. As a result, no entanglement and trimming between the mono yarns contained in the luminance-enhanced film do not occur, so that no phenomenon occurs. As a result, not only the defects appear in the luminance-enhanced film but also the reverse polarization phenomenon does not appear, so that the luminance can be maintained uniformly.

[Relationship 1]

A = number of islands in mono yarn / number of mono yarns forming one plywood

First, step (1) will be described. In the step (1), one of the weft yarns or the warp yarns is a birefringent island-in-the-sea yarn having an A value of 500 or more and the other one is a fiber.

Specifically, in the conventional birefringent island-in-the-sea yarn, when the number of islands is 300, 50 strands are used, or when the number of islands is 1016, 12 strands are used. The values are 6, 84.7, far below 500. In addition, when the number of islands is 127, 48 strands are used together, or when the number of islands is 297, 8 strands are used together. Substituting this into Equation 1, the A values are 2.6 and 37.1, respectively. Much less crazy.

In contrast, as described above, when the values of 12192 degrees (1 strand), 6096 degrees (2 strands), 25040 degrees (1 strand), and 5008 degrees (5 strands) are used as birefringent seams, respectively, the A values are 12192, 3048, and 25040. In other words, it is well over 500 since it is 1001.6. At this time, since the use of mono yarns rather than plunging multiple strands significantly reduces the possibility of occurrence of hair phenomena due to fiber entanglement and fiber trimming, more preferably A value is 1000 or more, 10000 or more than 20000. It is advantageous to use birefringent island-in-the-sea yarn, and most preferably, the use of mono- or two strands of birefringent island-in-the-sea yarn with 10000 or 20,000 or more islands is most effective for preventing fiber entanglement and woolen phenomenon. .

Furthermore, if the birefringent island-in-the-sea yarns are not fused with mono yarns having the same number of island components, and the mono yarns having various numbers of island components are fused together (for example, eight mono yarns with 297 islands and FIG. In the case of 48 mono yarns with 127 parts), the average value can be defined as the number of island parts in mono yarn.

On the other hand, if only one or two strands of birefringent islands in which the number of islands is 1016 degrees is used in order to prevent the phenomenon, the range of the value of A may be satisfied. It is not preferable because it is lowered. Therefore, according to an aspect of the present invention, the birefringent island-in-the-sea yarn may have a sum of the number of the island portions of the entire strands spliced together may be 10,000 or more. In addition, the number of islands of the mono-refraction islands of the mono yarns may be 5000 or more, more preferably, the number of islands of the birefringent islands in the mono yarns may be more than 10,000, most preferably the number of islands 20,000 Can be more than.

According to an aspect of the present invention, the diameter of the monofilament of the birefringent island-in-the-sea yarn may be 30 μm or more. If the diameter of the mono yarn is less than 30㎛ entanglement between the mono-fibers and the problem that some fibers are trimmed in the weaving and stretching process may occur (see Examples and Comparative Examples). Preferably, the mono yarn diameter of the birefringent island-in-the-sea yarn may be 40 ~ 100㎛. In addition, according to an aspect of the present invention, the island-in-the-sea yarn may be 15 to 500 denier / 1 to 6 strands, more preferably 20 to 60 denier / 1 to 4 strands. If the birefringent sea island is less than 20 denier, the residence time of the polymer raw material is long, so that pyrolysis may occur, and the strength is low, and the radioactivity may be lowered. Intensive flow can cause radioactive degradation. In addition, when the number of strands to be spliced exceeds 7, trimming may occur in the spinning or stretching process.

As described above, FIG. 2 and FIG. 3 is a lower portion plate of FIG. 4 as the above-described detained partial plate including a plurality of injection portions and a plurality of the injection portions of the spinneret for manufacturing sea islands disclosed in Korean Patent Application No. 2009-12138. In combination with this, the number of the birefringent islands in FIG. 5 is 1016. The Korean Patent Application No. 2009-12138 related to this is inserted as a reference of the present invention.

By the way, the birefringent island-in-the-sea yarn is radiated through the lower detent plate forming only one discharge port as shown in FIG. 8 rather than using the lower detention plate of FIG. In this case, as shown in FIG. 9, a birefringent island-in-the-sea yarn (mono yarn) having a number of island portions of 12192 and a diameter of 66 μm may be manufactured, and Korean Patent Application No. 2010-0028219 is a spinneret for manufacturing island-in-the-sea yarn related to the present invention. It is inserted as a reference to, but is not limited to this, if it is in accordance with the object of the present invention can be produced sea island thread through various forms of spinneret.

Specifically, FIG. 8 is a cross-sectional view of the lower holding plate of the spinneret for manufacturing island-in-the-sea yarn manufacturing according to an aspect of the present invention. It is formed to flow toward 810 and can be designed in various numbers and shapes according to the arrangement of the spinneret. The discharge holes 810 may finally discharge polymers collected through the flow paths 820 and 821, and may have a smaller number of discharge holes 820 and 821 than the number of polymer injection parts, and most preferably, one discharge hole 810 may be used. Can be formed. 9 is a sea island yarn radiated through this can be produced a sea island yarn (mono yarn) having a number of 12192 pieces and a diameter of 40 ~ 100㎛. The island-in-the-sea yarn of FIG. 9 has a space in which the island portion is not dense at the central portion thereof, so that the seam-bonding phenomenon does not occur.

 On the other hand, the spinneret of the present invention, like the spinneret for manufacturing a sea island yarn, the diameter of the lower billet plate, which is a portion where the actual islands and yarns are discharged, becomes narrower than that of the upper portion of the spinneret, so that the cross section of the spinneret may have a funnel shape as a whole. have. At this time

The shape of the cross-section of the detention part partial plate of the present invention may be circular, but it is possible to design by deforming to various shapes of the detention part partial plate according to the shape of the desired island-in-the-sea. The diameter of the cross section of may vary depending on the diameter of the desired island-in-the-sea yarn, but may preferably be 70 ~ 250mm. In addition, the thickness of the detentional partial plate may be 10 ~ 30㎜ but is not limited thereto. The diameter of the lower retainer plate is typically the same as or smaller than the diameter of the upper portion of the upper plate, the diameter of the discharge port may be 0.2 ~ 1.0 mm, the length of the flow path may be 40 ~ 120 mm, the width of the flow path is 4 ~ 10 It may be mm, but is not limited thereto and may be variously designed according to the specifications of the desired island.

10 and 11 are optical micrographs of the woven fabric 100 woven from the birefringent island-in-the-sea yarn of FIG. 9 without using the monofilament itself as the warp 101 and using the isotropic fibers as the weft 102. As a result, birefringent islands satisfying the diameter range of the mono yarns of the present invention can be confirmed that unlike the birefringent islands that do not satisfy the mono yarn trimming and woolen phenomenon.

On the other hand, the birefringent island-in-the-sea yarn (monosa) of FIG. 9 described above is merely an example, and in fact, by appropriately combining the numbers and diameters of the discharge holes included in the upper plate and the lower plate having various configurations and numbers of drawing portions. Birefringent islands of various sizes and thicknesses can be produced. In other words, in the case of manufacturing a single discharge port from a spinneret having 1200 number of islands and 8 individual ejection openings, a birefringent island-in-the-sea yarn (monosa) having 9600 islands may be produced.

Meanwhile, when the birefringent islands are radiated using the upper portion distribution plate of FIG. 3 and the lower portion plate of FIG. 8, the case of islands having more than 20,000 islands is concentric with a spinning core as shown in FIG. 3. In the case of arranging the fins, the density of the fins can be difficult to manufacture. Accordingly, according to an aspect of the present invention, as shown in FIGS. 12 and 13, a spinneret for manufacturing island-in-the-sea yarn was sought to solve the above-mentioned problems, and related Korean Patent Application No. 2010-0027670 refers to the present invention. It is inserted as, but this corresponds to the examples and various forms of spinnerets can be designed and used as long as it meets the object of the present invention.

Specifically, FIG. 12 is a cross-sectional view of the detention part partial plate 120 of the spinneret for producing island-in-the-sea yarn manufacturing according to an aspect of the present invention, and is formed in the center and prevents the joining of the core part 121 and the core part 121. A plurality of island component supply paths 122 are formed radially around the center and are formed along the outer periphery of the island component supply units 123 and 124 and the island component supply units 123 and 124 formed therein, and a plurality of sea component supply units. A plurality of sea component supply unit 125 including a furnace is included. A plurality of island component supply paths 124 are included in the island component supply unit 122. Since about 800 to 1400 island component supply paths 124 may be formed in one island component supply unit 121, 1252 island component supply paths 124 may be formed in one island component supply unit 121. In the case where the number of the island component supply parts 121 is 20, the number of the island portions of the radiated birefringent island-in-the-sea yarn is approximately 25,000.

Further, the depressor partial plate of the spinneret for producing a pizza type island-in-the-sea yarn surrounds one island component supply unit 121 with a sea component supply unit 123, and does not form a island component supply unit in the core portion 122 of the spinneret. You may not. As a result, the sea component of the birefringent island-in-the-sea yarn can easily penetrate into the inside of the island component, and the center portion, which is a portion where the island component is concentrated in the spinneret for manufacturing the island-in-the-sea yarn, is empty, so that the joint formation phenomenon occurs when the number of island components is large. It will not appear.

On the other hand, as long as the sea islands are manufactured and the degree of prevention of conjugation can be prevented, the number of sea component supply paths included in one sea component supply unit is not limited and may be variously designed according to the specifications of the sea islands to be manufactured. The number of sea component supply paths included in one sea component supply unit may be 3 to 25 pieces, and the total number of sea component supply paths may be 60 to 2500 pieces. In addition, the number of sea component supply paths formed in the sea component supply unit 126 continuously formed along the outer circumference of the core unit 121 may be 20 to 500.

Meanwhile, the diameters of the island component supply passage and the sea component supply passage used in the present invention may be variously designed according to the composition of the prepared island-in-the-sea yarn. Preferably, the diameter of the island component supply passage is 0.1 to 0.3 mm, and the sea component The diameter of the supply passage may be 0.2 to 2.0 mm, but is not limited thereto.

In addition, the shape of the cross-section of the detention part partial plate of the present invention may be circular, but it is possible to design by deforming to various shapes of the detention part partial plate according to the shape of the island-in-the-sea yarn, if the shape of the cross-section is a detention part The diameter of the cross section of the backplate may vary depending on the diameter of the desired island-in-the-sea yarn, but may preferably be 70 to 250 mm. In addition, the thickness of the detentional partial plate may be 10 ~ 30㎜ but is not limited thereto.

FIG. 13 is a lower stopper plate according to an aspect of the present invention and may be used in combination with the upper part partial plate of FIG. 12. Specifically, the polymer supplied from the island component supply part 121 and the sea component supply part 123 may be a flow path ( 131 may be collected and discharged along the discharge holes 132. The diameter of the discharge port of the lower plate may be 0.2 ~ 1.0mm and the length of the flow path may be 40 ~ 120mm, the width of the flow path may be 3 ~ 10mm. The width of the lower plate may be less than or equal to the width of the upper portion of the upper plate, the length may be 3 ~ 30mm, but is not limited thereto.

Furthermore, in order to facilitate the distribution and mixing of island components and sea components in addition to the detention part partial plate of the present invention, forming a spinneret by providing a separate distribution plate with an appropriate number on the upper part and / or the lower part part of the depart part distribution plate. It is possible.

FIG. 14 is a monocomponent of birefringent sea island yarns (coated component number: 25040, diameter: 66.5 μm) manufactured through spinnerets including the upper portion plate of FIG. 12 and the lower plate of FIG. Even when the number of blocks exceeds 20,000, the conjugation phenomenon does not occur.

Figure 15 can be seen that the birefringent island-in-the-sea yarn (mono yarn) of FIG. 14 described above as a warp and the birefringent island-in-the-sea yarn used as the warp yarn as a woven fabric with the isotropic fibers as a weft yarn does not occur.

On the other hand, the above-described birefringent islands for spinning yarn manufacturing spinneret is characterized in the upper portion of the upper plate and the lower plate, respectively, and the combination and the other configuration of the spinneret for manufacturing a sea island yarn can be applied. Furthermore, the above-described birefringent island-in-the-sea yarn manufacturing spinneret and a method of manufacturing the birefringent island-in-the-sea yarn using the same are examples for satisfying the relational formula 1 of the present invention, and in fact, the birefringent island-in-the-sea yarn that satisfies the relational formula 1 of the present invention is manufactured by various methods. You can do it.

As a result, when the birefringent island-in-the-sea yarn satisfies the above-mentioned relational expression 1, the luminance-enhanced film including the same does not generate entanglement between the birefringent island-in-the-sea yarns (mono yarn), so that the appearance of the fibrous band is not improved. In addition, even when using bi-refractive seaweed yarns in the form of mono yarns without going through a separate weaving process, only a few strands of coarse fibers are spliced together, so that some fibers are not trimmed in the spinning or stretching process, resulting in a cow's phenomenon. Can be blocked. As a result, the reverse polarization effect does not occur, and thus the light modulation efficiency can be maintained, and since the defects do not occur in the luminance-enhanced film, the appearance quality of the luminance-enhanced film can be dramatically improved. In addition, the weaving process can be improved because the weaving process does not occur by interfering with the weft due to poor opening movement during the weaving process.

According to another aspect of the present invention, when the birefringent island-in-the-sea yarn itself is included in the luminance-enhanced film, the birefringent island-in-the-sea yarn is easily moved in the lamination process and the like, so that it is difficult to properly arrange it. Therefore, when the woven fabric including the birefringent island-in-the-sea yarn is woven and the fabric is placed between the substrates and laminated, the birefringent island-in-the-sea yarn is fixed so that it can be properly disposed. However, when the birefringent island-in-the-sea yarn in the luminance-enhanced film is inserted into the form of the fabric rather than the fiber itself, when it is included and used in the liquid crystal display, the light is irradiated from the outside even when the fiber constituting the fabric is used as a transparent material. (In the case of the light passing through the luminance-enhanced film in the light source of the liquid crystal display) The phenomenon that the inner fabric (fiber) is visible to the outside appeared to be a big obstacle to commercialization.

Accordingly, in the present invention, the birefringent island-in-the-sea yarn is woven into the fabric, one of the weft or warp yarn of the fabric is a birefringent island-in-the-sea yarn and the other is a fiber, the melting start temperature of the island portion of the birefringent island-in-the-sea yarn melts the fiber The above problem has been solved by providing a luminance-enhanced film higher than temperature.

First, the fabric included in the luminance-enhanced film of the present invention will be described with reference to FIG. 10 is a picture of the fabric that can be used in the present invention, first, the fabric 100 may be made of a weft 102 and a warp 101, either of which weft 102 or warp 101 is It is a birefringent island-in-the-sea yarn and the other is a fiber. In other words, when the birefringent island-in-the-sea yarn is used as the weft 102, the fiber becomes the warp 101, and when the birefringent island-in-the-sea yarn is used as the warp 101, the fiber becomes the weft 102. Weft and warp constituting the fabric may be a transparent material or a translucent material so that light can be transmitted according to the purpose.

As the next step (2), the woven fabric is placed between the substrates and the lamination process is performed. Specifically, the melting start temperature of the island portion of the birefringent island-in-the-sea yarn may be higher than the melting temperature of the fiber. Through this, the fabric is placed between the substrates and subjected to heat and / or pressure to perform the lamination process when the lamination process is carried out at a temperature between the melting temperature of the fiber and the melting start temperature of the coating portion. It is not melted because it is not, but because the lamination process is performed at a temperature higher than the melting temperature of the fiber, the fiber is partially or fully melted. As a result, the weaved weft or warp fibers are melted in the lamination process and become part of the substrate, leaving only the birefringent islands in the final luminance-enhanced film. Therefore, the fiber visible phenomenon occurring when the fabric is included can be remarkably improved, and since the molten fiber can serve as an adhesive, the fabric and the substrate can be bonded without a separate adhesive. Therefore, the melting initiation temperature of the island portion of the birefringent island-in-the-sea yarn is higher than the melting temperature of the fiber, but preferably the melting initiation temperature of the island portion of the birefringent island-in-the-sea yarn may be 30 ° C. or more higher than the melting temperature of the fiber, and more preferably. Preferably higher than 50 ° C.

Meanwhile, the melting start temperature of the island portion of the birefringent islands may be higher than the melting temperature of the sea portion, and more preferably, the melting start temperature of the island portion of the birefringent islands may be 30 ° C. or more higher than the melting temperature of the sea portion. have. As a result, the sea portion of the birefringent island-in-the-sea yarn may be partially or fully melted. As a result, some or all of the fibers and / or sea parts may be melted, thereby improving fiber appearance and bonding the fabric and the substrate without a separate adhesive. On the other hand, according to a preferred embodiment of the present invention, the melting start temperature of the island portion of the birefringent islands may be 130 ~ 430 ℃, the melting temperature of the isotropic fibers may be 100 ~ 400 ℃, the birefringent islands Melting temperature of the sea portion of the yarn may be 100 ~ 400 ℃ and the lamination temperature may be 100 ~ 420 ℃ but is not limited thereto.

After all, the luminance-enhanced film including the fabric according to the present invention has a melting start temperature of the isotropic fibers forming the weft or warp of the fabric is lower than the melting start temperature of the birefringent islands of the warp yarn forming another weft or warp, the melting start temperature of the isotropic fibers When the lamination process is performed at a temperature between the temperature of the birefringent island-in-the-sea yarn and some or all of the isotropic fibers are melted, it is possible to solve the fiber visible phenomenon of the luminance-enhanced film. Furthermore, since the melting temperature of the sea portion of the birefringent island-in-the-sea yarn is lower than the melting start temperature of the island portion, when the lamination process is performed at the temperature therebetween, part or all of the sea portion is melted and the lamination process is performed at the temperature therebetween. If part or all of the seam is melted to have the effect of laminating the sheet and the fabric into a single layer without a separate adhesive.

According to another aspect of the invention, the fabric may be woven into an asymmetrical tissue such that the birefringent islands are more exposed to the surface than the fibers. The surface of the fabric refers to either side of the fabric. The asymmetrical tissue refers to a fabric of a fabric in which the intersection point of the warp and the weft is small, and either the warp or the weft floats on the surface in a long continuous manner. The term intersection refers to staggered positions where the warp and weft are shifted up and down. Such asymmetrical fabrics can minimize the appearance of the fabric pattern (traces of the intersection of the warp and weft yarns) on the luminance-enhanced film. The fabric and the substrate may be combined by various methods such as vacuum hot press laminating, and these methods may generally leave the pattern of the fabric on the luminance-enhanced film. In other words, when the vacuum hot press lamination is described as an example, it is preferable that the non-birefringent yarn loses its yarn form after the vacuum hot press lamination process, wherein the birefringence at the intersection point of the weft and the warp by the pressure of the hot press is lost. This results in a change in the shape of the island-in-the-sea yarn, resulting in a pattern of intersections on the luminance-enhanced film. The pattern of intersections may cause moiré on the LCD screen, but the birefringent islands are exposed to the surface more than the fibers. This problem can be solved when woven into an asymmetrical tissue.

Next, the description that can be used in the present invention will be described. Materials used for the substrate include thermoplastic and thermosetting polymers that transmit a desired wavelength of light and may be a transparent or translucent material that is easy to transmit light. Preferably suitable substrates may be amorphous or semicrystalline and may comprise homopolymers, copolymers or blends thereof. Specifically poly (carbonate) (PC); Syndiotactic and isotactic poly (styrene) (PS); Alkyl styrenes; Alkyl, aromatic and aliphatic ring containing (meth) acrylates including poly (methylmethacrylate) (PMMA) and PMMA copolymers; Ethoxylated and propoxylated (meth) acrylates; Polyfunctional (meth) acrylates; Acrylated epoxy; Epoxy; And other ethylenically unsaturated substances; Cyclic olefins and cyclic olefin copolymers; Acrylonitrile butadiene styrene (ABS); Styrene acrylonitrile copolymer (SAN); Epoxy; Poly (vinylcyclohexane); PMMA / poly (vinylfluoride) blends; Poly (phenylene oxide) alloys; Styrene block copolymers; Polyimide; Polysulfones; Poly (vinyl chloride); Poly (dimethylsiloxane) (PDMS); Polyurethane; Unsaturated polyesters; Polyethylene; Poly (propylene) (PP); Poly (alkane terephthalates) such as poly (ethylene terephthalate) (PET); Poly (alkane naphthalate) such as poly (ethylene naphthalate) (PEN); Polyamides; Ionomers; Vinyl acetate / polyethylene copolymers; Cellulose acetate; Cellulose acetate butyrate; Fluoropolymers; Poly (styrene) -poly (ethylene) copolymers; PET and PEN copolymers, including polyolefin PET and PEN; And poly (carbonate) / aliphatic PET blends. More preferably, polyethylene naphthalate (PEN), polyethylene naphthalate copolymer (co-PEN) polyethylene terephthalate (PET), polycarbonate (PC), polycarbonate (PC) alloy, polystyrene (PS), heat-resistant polystyrene (PS), polymethyl methacrylate (PMMA), polybutylene terephthalate (PBT), polypropylene (PP), polyethylene (PE), acrylonitrile butadiene styrene (ABS), polyurethane (PU), polyimide (PI), polyvinyl chloride (PVC), styrene acrylonitrile mixture (SAN), ethylene vinyl acetate (EVA), polyamide (PA), polyacetal (POM), phenol, epoxy (EP), urea. (UF.MF), Unsaturated polyester (UP), Silicone (SI), Elastomer, Cycloolefin polymer (COP, Japan ZEON, JSR) can be used alone or in combination, more preferably birefringence The same components as the sea parts of the yarn may be used. Furthermore, the substrate may contain additives such as antioxidants, light stabilizers, heat stabilizers, lubricants, dispersants, ultraviolet absorbers, white pigments, fluorescent whitening agents, and the like, and the substrate is optically isotropic, so long as the above properties are not impaired. Can be.

On the other hand, the substrate may be configured in the same manner as the components and optical properties of the sea portion and / or fiber components and the optical properties of the substrate in consideration of various physical properties. In this case, part or all of the substrate may be melted in the lamination process, thereby improving adhesion between the birefringent islands and the substrate without using a separate adhesive. In this case, the base material may have a three-stage layer. Specifically, the three-stage layer may have a laminated structure of skin layer (B layer) / core layer (A layer) / skin layer (B layer) by coextrusion of a polymer. Can be configured. The skin layer corresponding to the fabric and corresponding to the outside of the sheet may have the same melting temperature as sea areas and / or fibers in order to improve adhesion with birefringent island-in-the-sea yarns, and the core layer may deform the sheet due to heat generation of the lamp. Materials with higher melting temperatures than sea areas and / or fibers may be used to prevent this.

Next, the fibers that can be used as the weft or warp of the fabric of the present invention will be described. The fiber may be woven with birefringent island-in-the-sea yarn to form a fabric, and may be used without limitation as long as it satisfies the above-mentioned temperature conditions. Preferably, the fiber is optical in view of being woven perpendicular to the birefringent island-in-the-sea yarn. It is preferable that it is isotropic fiber. This is because when the fiber also has birefringence, light modulated through the birefringent island-in-the-sea yarn may not pass through the fiber. On the other hand, the fibers may be used alone or mixed with polymer fibers, natural fibers, inorganic fibers (glass fibers, etc.), and more preferably, fibers of the same material as the sea component of the birefringent island-in-the-sea yarn. Furthermore, according to another preferred embodiment of the present invention, the refractive index of the sea portion of the birefringent island-in-the-sea yarn may be the same as the refractive index of the substrate.

Next, the birefringent island-in-the-sea yarn used as the weft or warp yarn of the fabric of the present invention will be described. The birefringent island-in-the-sea yarn that may be used in the present invention may have different optical characteristics of the island portion and the sea portion in order to maximize light modulation efficiency. More preferably, the island portion is anisotropic and the sea portion may be isotropic.

Specifically, in an island-in-the-sea island comprising an optically isotropic sea portion and an island portion having anisotropy, the magnitude of the substantial coincidence or mismatch of the refractive indices along the X, Y, and Z axes in space affects the degree of scattering of the polarized light along the axis. Crazy In general, the scattering power varies in proportion to the square of the refractive index mismatch. Thus, the greater the degree of mismatch in refractive index along a particular axis, the more strongly scattered light polarized along that axis. Conversely, when the mismatch along a particular axis is small, the light polarized along that axis is scattered to a lesser extent. If the refractive index of the sea portion along a certain axis substantially coincides with the refractive index of the island portion, the incident light polarized by an electric field parallel to this axis will not be scattered regardless of the size, shape, and density of the portion of the island. Will pass. Also, when the refractive indices along that axis are substantially coincident, the light beam passes through the object without being substantially scattered. More specifically, FIG. 13 is a cross-sectional view showing a path of light transmitted through the birefringent island-in-the-sea yarn of the present invention. In this case, the P wave (solid line) is transmitted without being affected by the interface between the birefringent island-in-the-sea yarn and the interface between the island and the sea inside the birefringent island-in-the-sea yarn, while the S-wave (dotted line) The modulation of light occurs due to the influence of the birefringence interface between the boundary surface of the island and the sea portion inside the islands of the islands and / or birefringent islands.

The above-mentioned light modulation phenomenon at the birefringent interface mainly occurs at the interface between the substrate and the sea portion within the interface between the substrate and the birefringent island-in-the-sea yarn and inside the birefringent island-in-the-sea yarn. Specifically, when the optical property of the base material is isotropic, light modulation occurs at the interface between the base material and the birefringent island-in-the-sea yarn as in the case of ordinary birefringent fibers. More specifically, the refractive index of the substrate and the birefringent island-in-the-sea yarn may have a difference in refractive index of 0.05 or less in two axial directions, and a difference in refractive index of one remaining axial direction may be 0.1 or more. More specifically, when the refractive index in the x-axis direction of the substrate is nX1, the refractive index in the y-axis direction is nY1 and the refractive index in the z-axis direction is nZ1, and the refractive indexes of the birefringent island-in-the-sea yarns are nX2, nY2 and nZ2, At least one of the X, Y, and Z-axis refractive indices of the island-in-the-sea yarn may coincide, and the refractive index of the birefringent island-in-the-sea yarn may be nX2> nY2 = nZ2.

On the other hand, in the present invention, the optical quality of the island portion and the sea portion of the birefringent island-in-the-sea yarn is advantageous to create a birefringent interface. Specifically, when the island portion is anisotropic and the sea portion is isotropic, a birefringence interface may be formed at the interface between the island portion and the sea portion, and more preferably, the refractive index may be 0.05 or less in difference between the two indexes. It is preferable that the difference in refractive index with respect to one axial direction is 0.1 or more. In this case, P wave passes through the birefringent interface of island-in-the-sea yarn, but S wave can cause light modulation. In more detail, the refractive index in the x-axis direction in the longitudinal direction of the island portion of the birefringent island-in-the-sea yarn is nX3, the refractive index in the y-axis direction is nY3 and the refractive index in the z-axis direction is nZ3, and the refractive index in the x-axis direction of the sea portion When the refractive index in the nX4 and y-axis directions is nY4 and the refractive index in the z-axis direction is nZ4, at least one of the X, Y, and Z-axis refractive indices of the substrate and the birefringent island-in-the-sea yarn may coincide, and the refractive indices of the nX3 and nX4 The absolute value of the difference of may be 0.1 or more. Most preferably, the difference in refractive index in the longitudinal direction of the sea portion and the island portion of the island-in-the-sea yarn is 0.1 or more, and the optical modulation efficiency may be maximized when the refractive indices of the sea portion and the island portion in the remaining two axial directions substantially coincide. have. On the other hand, it is advantageous to increase the light modulation efficiency when the refractive index of the sea portion of the substrate and the birefringent islands.

Therefore, it is effective to improve the light modulation efficiency by selecting a material in which the refractive indexes in the two axial directions are substantially the same in the island portion and the sea portion of the birefringent islands.

The sea portion and / or island portion of the birefringent island-in-the-sea yarn that may be used in the present invention may be polyethylene naphthalate (PEN), copolyethylene naphthalate (co-PEN), polyethylene terephthalate (PET), polycarbonate (PC), Polycarbonate (PC) alloy, polystyrene (PS), heat-resistant polystyrene (PS), polymethyl methacrylate (PMMA), polybutylene terephthalate (PBT), polypropylene (PP), polyethylene (PE), acrylo Nitrile Butadiene Styrene (ABS), Polyurethane (PU), Polyimide (PI), Polyvinyl Chloride (PVC), Styrene Acrylonitrile Mixture (SAN), Ethylene Vinyl Acetate (EVA), Polyamide (PA), Poly It may be at least one of acetal (POM), phenol, epoxy (EP), urea (UF), melanin (MF), unsaturated polyester (UP), silicone (SI), elastomer and cycloolefin polymer. Preferably, the material and the sea portion have substantially the same refractive index in two axial directions, but selecting a material having a large difference in refractive index in one axial direction is effective to improve the light modulation efficiency. However, most preferably, polyethylene biphthalate (PEN) is used as the island portion as the birefringent island-in-the-sea yarn 31, and copolyethylene naphthalate and a polycarbonate alloy are used alone or in a mixed state. The brightness is remarkably improved as compared with the birefringent island-in-the-sea yarn manufactured by the conventional material. In particular, when the polycarbonate alloy (alloy) is used as the sea portion, it is possible to produce a birefringent island-in-the-sea yarn having the best optical modulation properties. In this case, the polycarbonate alloy is preferably made of polycarbonate and modified glycol polycyclohexylene dimethylene terephthalate (PCTG), and more preferably polycarbonate and modified glycol poly Cyclohexylene dimethylene terephthalate (PCTG) is a polycarbonate alloy consisting of a weight ratio of 15: 85 ~ 85: 15 is effective to increase the brightness. If the polycarbonate is added less than 15%, the viscosity of the polymer required to secure the radioactivity is high, and the ordinary spinning machine cannot be used. If the polycarbonate is more than 85%, the glass transition temperature increases, and after the nozzle discharge, the radiation tension increases to secure radioactivity. Has a difficult problem.

Most preferably, the polycarbonate and the modified glycol polycyclohexylene dimethylene terephthalate (PCTG) in a weight ratio of 4: 6 to 6: 4 exhibit the best effect on brightness enhancement. Furthermore, it is effective to improve the light modulation efficiency by selecting a material in which the refractive index in the two axial directions is substantially the same, but the difference in the refractive index in the one axial direction is large.

On the other hand, methods for changing an isotropic material to birefringence are commonly known and, for example, when drawn under suitable temperature conditions, the polymer molecules can be oriented so that the material becomes birefringent.

On the other hand, according to a preferred embodiment of the present invention, the luminance-enhanced film of the present invention may have a structured surface layer on its surface, and more specifically, the structured surface layer may be formed on the surface from which light is emitted. The structured surface layer may be prismatic, lenticular or convex. In detail, the surface on which the light on the luminance-enhanced film is emitted may have a curved surface having a convex lens shape. The curved surface may focus or defocus light transmitted through the surface. In addition, the light exit surface may have a prism pattern.

Next, a method of manufacturing the luminance-enhanced film of the present invention will be described. After weaving the fabric having the above-described configuration, the fabric may be placed between the substrate and the substrate and then laminated. At this time, the lamination process may be performed in a roll-to-roll, hot press, etc., but preferably carried out in a vacuum hot press is effective in preventing the generation of bubbles to improve the adhesion and brightness. In this case, the degree of vacuum of the pressurizing and heating steps is 5 to 500 torr, the applied pressure is 1.0 to 100kgf / cm ² and the process time is preferably 1 to 30 minutes. As described above, the lamination temperature may be appropriately selected and applied at a temperature between the melting start temperature of the island portion of the birefringent island-in-the-sea yarn and the melting temperature of the fiber and / or sea portion. On the other hand, when the vacuum degree is less than 5 torr, there is a fear that the process efficiency is lowered, and when it exceeds 500 torr, there is a fear that bubble removal is insufficient. In addition, the applied pressure is 1.0kgf / cm ² Less than When the adhesion of the film may not be sufficient and when it exceeds 100 kgf / cm ² , the pressure may be excessive to disturb the tissue of the fabric and collapse the arrangement of the fibers. If the process time is less than 1 minute, bubble removal and adhesion may be insufficient, and if it exceeds 30 minutes, it is not preferable in terms of process efficiency.

Hereinafter, the present invention will be described in detail by Examples and Experimental Examples. The following Examples and Experimental Examples are only illustrative of the present invention, and the scope of the present invention is not limited to the following Examples and Experimental Examples.

&Lt; Example 1 >

Isotropic PC alloy containing polycarbonate and modified glycol polycyclohexylene dimethylene terephthalate (PCTG) in a 5: 5 solution (nx = 1.57, ny = 1.57, nz = 1.57, melting temperature: 145 ° C) , Anisotropic PEN (nx = 1.88, ny = 1.57, nz = 1.57, melting start temperature: 262 ° C.). Birefringence having the cross section of FIG. 9 by supplying the island component and the sea component to a spinneret including a portion of the detention plate including twelve island component supply parts corresponding to FIG. 3 and a lower compartment plate having one discharge port of FIG. 8. Sung sea island yarn (monosa yarn, number of island components: 12192 pieces, diameter: 66㎛) was prepared.

The birefringent island-in-the-sea yarn (monosa) was inclined (40de / 1fila), and the same isotropic PC alloy fiber (melting temperature: 145 ° C) was manufactured at 60/24, and weaved into a fabric. It was. The fabrics were then subjected to two isotropic PC alloy sheets [skin / core / skin three-layer structure, core layer (melting temperature: 149 ° C., 150 μm, polycarbonate), skin layer (melting temperature: 145 ° C., 30 μm, Polycarbonate alloy (same as the sea component)], and then, using a vacuum hot press (manufactured by MEIKI Co., Ltd.) under a vacuum of 20torr for 20 minutes at a temperature of 150 ° C (lamination temperature) and a pressure of 15kgf / cm ² . By heating / pressing, a luminance-enhanced film having a thickness of 400 μm was manufactured.

10 is a SEM photograph of the surface of the fabric produced in Example 1. It can be seen from the photograph that the trimming does not occur in the birefringent islands used as a slope.

<Example 2>

Isotropic PC alloy containing polycarbonate and modified glycol polycyclohexylene dimethylene terephthalate (PCTG) in a 5: 5 solution (nx = 1.57, ny = 1.57, nz = 1.57, melting temperature: 145 ° C) , Anisotropic PEN (nx = 1.88, ny = 1.57, nz = 1.57, melting start temperature: 262 ° C.). In order to obtain a birefringent island-in-the-sea yarn having the same cross-section as in FIG. 14, the composition is injected into a spinneret including a portion of the upper portion of the depressor plate (12 outlets) corresponding to FIG. 12 and a lower plate (1 outlet) of FIG. 13. Birefringent island-in-the-sea yarn (mono sand, island component number: 25040, diameter: 66.5 mu m) was prepared. At this time, POY (partial alignment yarn) 85/1 having a spinning speed of 2500MPM was prepared, and the FY 40/1 was prepared by performing 2.1 times stretching at a temperature of 140 degrees.

The prepared birefringent island-in-the-sea yarn (monosa) was inclined (40de / 1fila), and the isotropic PC alloy fiber (melting temperature: 145 ° C) having the same composition as the sea component was used as the weft yarn (POY 60/24). Weaving with fabric. Thereafter, a lamination process was performed under the same conditions as in Example 1 to prepare a luminance-enhanced film having a thickness of 400 μm.

15 is a SEM photograph of the surface of a fabric prepared in Example 2. FIG. It can be seen from the above photograph that the trimming and the cattle phenomenon do not occur in the birefringent islands used as a slope.

Comparative Example 1

Isotropic PC alloy containing polycarbonate and modified glycol polycyclohexylene dimethylene terephthalate (PCTG) in a 5: 5 solution (nx = 1.57, ny = 1.57, nz = 1.57, melting temperature: 145 ° C) , Anisotropic PEN (nx = 1.88, ny = 1.57, nz = 1.57, melting start temperature: 262 ° C.).

In order to obtain a birefringent island-in-the-sea yarn having a cross-section as shown in FIG. 5, the composition is introduced into a spinneret including the spherical partial plate corresponding to FIG. Mono yarn, island component number: 1016, diameter: 19㎛) was prepared. A POY 85de / 12fila was prepared at a spinning speed of 2500 MPM and a spinning temperature of 290 degrees, followed by 2.1 times stretching at 140 degrees to prepare FY 40de / 12fila. The fabrics were woven using the prepared island-in-the-sea yarn FY 40/12 two-ply yarns (80de / 24fila), and then inclined, and using the same isotropic PC alloy fibers (melting temperature: 145 ° C) as wefts. Thereafter, a lamination process was performed under the same conditions as in Example 1 to prepare a luminance-enhanced film having a thickness of 400 μm.

Figure 6 is a SEM photograph of the surface of the fabric prepared through Comparative Example 1. Through the above picture, it can be seen that entanglement and trimming (A, B, C) occurred between birefringent islands used as a slope.

The luminance-enhanced film produced by the manufacturing method of the present invention is excellent in light modulation performance and does not cause defects, and thus can be widely used in fields requiring modulation of light. Specifically, optical devices such as cameras and microscopes, automotive exterior materials, and mobile phones, LCDs, LEDs, and other high-brightness liquid crystal displays, projection displays, plasma displays, field emission displays, and electroluminescent displays may be widely used in flat panel display technologies. .

Although the present invention has been described in detail only with respect to the described embodiments, it will be apparent to those skilled in the art that various modifications and variations are possible within the technical spirit of the present invention, and such modifications and modifications belong to the appended claims. .

20: polymer injection portion, 40, 41, 42: discharge port

Claims (31)

(1) weaving either the weft or the warp is a birefringent island-in-the-sea yarn having an A value of 500 or more in relation 1 below and the other being a fiber;
(2) placing the woven fabric between the substrate and performing a lamination process.
[Relationship 1]
A = number of islands in mono yarn / number of mono yarns forming one plywood The method of claim 1,
And a melting start temperature of the island portion of the birefringent island-in-the-sea yarn is higher than the melting temperature of the fiber. The method of claim 1,
And a birefringent interface is formed at a boundary between the island portion and the sea portion of the birefringent island-in-the-sea yarn. The method of claim 1,
The fiber is a method of manufacturing a luminance-enhanced film, characterized in that the optical properties are isotropic fibers. The method of claim 1,
The fiber is a method of producing a luminance-enhanced film, characterized in that any one or more fibers selected from the group consisting of polymer fibers, natural fibers and inorganic fibers. The method of claim 1,
And a melting start temperature of the island portion of the birefringent island-in-the-sea yarn is higher than the melting temperature of the sea portion. The method of claim 1,
Melting start temperature of the coating portion of the birefringent island-in-the-sea yarn is 30 ℃ or more higher than the melting temperature of the fiber manufacturing method of the luminance-enhanced film. The method of claim 1,
Melting start temperature of the island portion of the birefringent island-in-the-sea yarn is 30 ℃ or more higher than the melting temperature of the sea portion manufacturing method of the luminance-enhanced film. The method of claim 1,
The fiber is a method of producing a brightness enhancement film, characterized in that the melting part or all. The method of claim 1,
A part or all of the sea portion of the birefringent island-in-the-sea yarn is melted manufacturing method of the luminance-enhanced film. The method of claim 1,
Method for producing a brightness-enhanced film, characterized in that the sea portion of the fiber and the birefringent island-in-the-sea yarn is the same component. The method of claim 1,
Wherein the optical property of the island portion of the birefringent island-in-the-sea yarn is birefringent, and the optical property of the sea portion is isotropic. The method of claim 1,
The lamination process is a manufacturing method of the luminance-enhanced film, characterized in that carried out at the temperature conditions of the relation 2.
[Relationship 2]
Melting temperature of the fiber (℃) <Lamination temperature (℃) <Melting start temperature of the coating part (℃) The method of claim 1,
The method of manufacturing a brightness enhancement film, characterized in that the A value is 1000 or more. The method of claim 1,
A method for producing a luminance-enhanced film, characterized in that the A value is 10000 or more. The method of claim 1,
A method for producing a brightness enhancement film, characterized in that the A value is more than 20000. The method of claim 1,
The birefringent island-in-the-sea yarn manufacturing method of the luminance-enhanced film, characterized in that the number of the island portion of the mono yarn is 5000 or more. The method of claim 1,
The birefringent island-in-the-sea yarn manufacturing method of the luminance-enhanced film, characterized in that the number of islands of the mono yarn is 10,000 or more. The method of claim 1,
The birefringent island-in-the-sea yarn manufacturing method of the luminance-enhanced film, characterized in that the number of the island portion of the mono yarn more than 20000. The method of claim 1,
The mono yarn diameter of the birefringent island-in-the-sea yarn is 30㎛ or more manufacturing method of the brightness reinforced film. The method of claim 1,
The diameter of the mono yarns of the birefringent island-in-the-sea yarn is 40 ~ 100㎛ manufacturing method of the brightness reinforced film. The method of claim 1,
The birefringent island-in-the-sea yarn manufacturing method of the brightness-enhanced film, characterized in that 15 ~ 200 denier / 1 to 6 strands. The method of claim 1,
The birefringent island-in-the-sea yarn manufacturing method of the luminance-enhanced film, characterized in that the mono yarns or 2 to 6 strands plyed. The luminance-enhanced film of claim 1, wherein the refractive index of the substrate and the birefringent island-in-the-sea yarn is 0.05 or less in two axial directions, and the difference in refractive index in one remaining axial direction is 0.1 or more. Manufacturing method. The substrate according to claim 1, wherein when the refractive index in the x-axis direction of the substrate is nX1, the refractive index in the y-axis direction is nY1, the refractive index in the z-axis direction is nZ1, and the refractive indices of the birefringent island-in-the-sea yarns are nX2, nY2, and nZ2. A method for producing a luminance-enhanced film, characterized in that at least one of the birefringent island-in-the-sea yarn X, Y, and Z-axis refractive indices coincides. The method of claim 25, wherein the refractive index of the birefringent island-in-the-sea yarn is nX2> nY2 = nZ2. The method of claim 1, wherein the refractive index of the sea portion and the island portion of the birefringent island-in-the-sea yarn has a difference in refractive index of 0.05 or less in two axial directions, the difference in refractive index of the remaining one axial direction is 0.1 or more Method of manufacturing reinforced film. The refractive index of the x-axis direction in the longitudinal direction of the island portion of the birefringent island-in-the-sea yarn is nX3, the refractive index in the y-axis direction is nY3 and the refractive index in the z-axis direction is nZ3, and the refractive index in the x-axis direction of the sea portion When the refractive index in the nX4, y-axis direction is nY4 and the refractive index in the z-axis direction is nZ4, at least any one of the X, Y, Z-axis refractive index of the base material and the birefringent island-in-the-sea yarn is produced. Way. 29. The method of claim 28, wherein the absolute value of the difference between the refractive indices of nX3 and nX4 is 0.1 or more. The method of manufacturing a brightness-enhanced film according to claim 1, wherein the refractive index of the sea portion of the birefringent island-in-the-sea yarn coincides with the refractive index of the base material. 13. The method of claim 12, wherein the fabric is woven into an asymmetrical structure such that the birefringent island-in-the-sea yarn is exposed to the surface more than the fiber.

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