KR20140021240A - Manufacturing method of reflective polarizer dispered polymer and device thereof - Google Patents

Abstract

A reflective polarizer with a dispersed polymer according to the present invention has excellent optical properties when a very small number of birefringent polymers are included in the reflective polarizer in comparison with an existing reflective polarizer with birefringent polymers having the same area as the reflective polarizer; has an advantage in covering the entire area of visible light using a plate-shaped polymer having various optical thicknesses; and eliminates a separate bonding step as a skin layer is formed on one or more sides of a core layer while the skin layer is melted. Therefore, the present invention significantly reduces production costs; and has an advantage in maximizing the optical properties of a reflective polarizer having a limited thickness.

Description

Manufacturing method and reflective polarizer dispered polymer and device

The present invention relates to a method and apparatus for manufacturing a reflective polarizer in which a polymer is dispersed, and more particularly, to a method and apparatus for manufacturing a reflective polarizer in which a polymer is dispersed, which can maximize a light modulation effect even when a small number of polymers are disposed in a substrate. To provide.

Flat panel display technology is mainly composed of liquid crystal display (LCD), projection display, and plasma display (PDP), which have already secured a market in the TV field. In addition, field emission display (FED) and electroluminescence display (ELD) And it is expected to occupy the field according to each characteristic. Liquid crystal displays are currently being used in a wide range of applications such as notebook computers, personal computer monitors, liquid crystal TVs, automobiles, and aircrafts, accounting for 80% of the flat panel market, and booming demand for LCDs worldwide.

Conventional liquid crystal displays place a liquid crystal and an electrode matrix between a pair of light absorbing optical films. In liquid crystal displays, the liquid crystal portion has an optical state that changes accordingly by moving the liquid crystal portion by an electric field generated by applying a voltage to the two electrodes. This process displays an image by using a polarized light in a specific direction as a 'pixel' containing information. For this reason, liquid crystal displays include a front optical film and a rear optical film that induce polarization.

  The optical film used in such a liquid crystal display does not necessarily have a high utilization efficiency of light emitted from the backlight. This is because 50% or more of the light emitted from the backlight is absorbed by the back side optical film (absorption type polarizing film). Therefore, in order to improve the utilization efficiency of the backlight in the liquid crystal display, a reflection type polarizer is provided between the optical cavity and the liquid crystal assembly.

  1 is a view showing the optical principle of a conventional reflective polarizer. Specifically, P polarization of light from the optical cavity to the liquid crystal assembly passes through the reflective polarizer to the liquid crystal assembly, and S polarized light is reflected from the reflective polarizer to the optical cavity, and then the polarization direction of the light in the diffuse reflection plane of the optical cavity. This randomized state is reflected and transmitted back to the reflective polarizer 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 reflective polarizer to the liquid crystal assembly.

The selective reflection of the S polarized light and the transmission of the P polarized light with respect to the incident light of the reflective polarizer are performed in such a manner that the refractive index of each optical layer in the state of alternately stacking the flat optical layer having the anisotropic refractive index and the flat optical layer having the isotropic refractive index The optical thickness of each of the optical layers in accordance with the difference and the elongation process of the laminated optical layer, and the change of the refractive index of the optical layer.

  That is, the light incident on the reflective polarizer repeats the reflection of the S polarized light and the transmission of the P polarized light while passing through each optical layer, and finally, only the P polarized light of the incident polarized light is transmitted to the liquid crystal assembly. On the other hand, as described above, the reflected S polarized light is reflected in the polarization state of the diffused reflection plane of the optical cavity in a randomized state and then transmitted to the reflective polarizer. As a result, it is possible to reduce the waste of power with loss of light generated from the light source.

However, the conventional reflective polarizer has an optical thickness and a refractive index between the optical layers that can be optimized for selective reflection and transmission of incident polarization by alternately stacking isotropic optical layers and anisotropic optical layers having different refractive indices. Since it is manufactured to have, there was a problem that the manufacturing process of the reflective polarizer is complicated. In particular, since each optical layer of the reflective polarizer 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. In addition, when the skin layer of the conventional polycarbonate is integrated with the core layer on which PEN-coPEN is alternately laminated through co-extrusion, peeling may occur due to the incompatibility member. There is a high risk of birefringence on the axis. Accordingly, in order to apply the polycarbonate sheet of the non-stretching process, there was no choice but to form an adhesive layer between the core layer and the skin layer. As a result, the addition of the adhesive layer process results in a decrease in yield due to external foreign matters and process defects. In general, when the polycarbonate non-stretched sheet of the skin layer is produced, birefringence occurs due to uneven shear pressure due to the winding process. In order to compensate, a separate control such as deformation of the polymer molecular structure and speed control of the extrusion line were required, resulting in a decrease in productivity. In addition, when the multilayer polarizer is manufactured through a feed block and a distributor, there are problems such as yellowing and carbonization caused by an increase in polymer residence time, as well as various thickness control. As a result, the reflective polarization function of one visible light wavelength region is realized. Therefore, in order to control the visible light region having a wavelength of 380 nm to 780 nm, two or more reflective polarization layers having different thicknesses must be extruded and produced through an adhesive process. As a result, there was a problem in that a defect rate generation and an operation cost occurred for each process.

Accordingly, a technical idea of arranging the birefringent polymer elongated in the longitudinal direction in the substrate to achieve the function of the reflective polarizer has been proposed. FIG. 2 is a perspective view of a reflective polarizer 20 including a rod-shaped polymer, in which the birefringent polymer 22 extending in the longitudinal direction is arranged in one direction in the substrate 21. The birefringent interface between the base material 21 and the birefringent polymer 22 causes a light modulation effect to perform the function of the reflection type polarizer. However, there is a problem that the light modulation efficiency is much lower than that of the alternating reflective polarizer described above, and in order to have a transmittance and reflectance similar to that of the alternating reflective polarizer, an excessively large number of birefringent polymers 22 are disposed in the substrate. There was a problem with the arrangement. Specifically, in the case of manufacturing a horizontal 32-inch display panel based on the vertical cross section of the reflective polarizer, in order to have optical properties similar to those of the stacked reflective polarizer described above in the substrate 21 having a width of 1580 mm and a height (thickness) of 400 μm or less, At least 100 million circular or elliptical birefringent polymers 22 having a cross-sectional diameter in the longitudinal direction of 0.1 to 0.3 μm should be included. In this case, not only the production cost is excessively high, but also the equipment becomes too complicated and It was almost impossible to manufacture the spinneret itself, which made it difficult to be commercialized.

In order to overcome this problem, a technical idea including a birefringent sea chart was proposed in the substrate. FIG. 3 is a cross-sectional view of a birefringent island-in-the-sea yarn included in the substrate, and the birefringent island-in-the-sea yarn may generate a light modulation effect at an optical modulation interface between the inner and sea portions of the inner portion, and thus, a very large number of the birefringent island Optical properties can be achieved even if the island-in-the-sea yarns are not disposed. However, since the fiber is a birefringent graphite sheet, compatibility with a base material such as a polymer, ease of handling, and adhesiveness have been encountered. Furthermore, due to the circular shape, light scattering is induced, and thus the reflection polarization efficiency of the visible wavelength is reduced, and the polarization characteristic is lowered compared to the existing products, thereby limiting the luminance improvement. As the area is subdivided, the voids cause the optical characteristic degradation due to light leakage, that is, optical loss. In addition, there is a problem in that the limitation of the reflection and polarization characteristics due to the limitation of the layer configuration due to the organization of the fabric form.

The present invention has been made to solve the above-described problem, the first problem to be solved by the present invention is that even when a very small number of birefringent polymers in the substrate as compared to the reflective polarizer comprising a conventional birefringent polymer It is to provide a method and apparatus for manufacturing a reflective polarizer having very excellent optical properties.

A second object of the present invention is to provide a method and apparatus for manufacturing a reflective polarizer capable of causing modulation for a wide range of light, including a dispersed polymer having a different optical thickness inside the reflective polarizer.

A third object of the present invention is to provide a method and apparatus for manufacturing a reflective polarizer which can be integrally formed without forming a separate adhesive layer between the core layer and the skin layer.

A method of manufacturing a reflective polarizer in which a polymer of the present invention is dispersed to solve the above problems includes a core layer having a plurality of first components dispersed in a second component and a skin layer formed on at least one surface of the core layer. CLAIMS 1. A method for manufacturing a polymer dispersed reflective polarizer, the method comprising: (1) supplying a first component, a second component and a skin layer component to the extruders, respectively; (2) forming an island-in-the-sea composite compound in which a plurality of first components are dispersed inside the second component, wherein the island-in-the-sea composite compound reflects an S wave of a desired wavelength and forms an optical thickness of the first components differently. To this end, the island-in-the-sea composites are prepared by injecting the first component and the second component transferred from the extruder into a single island-in-the-sea type extrusion mold including part or all of different diameter or cross-sectional areas of the island component feed passages. Forming (3) laminating at least one surface of the island-in-the-sea composites with the skin layer component transferred from the extrusion unit; And (4) inducing spreading in the flow control unit such that the first component of the island-in-the-sea composite compound in which the skin layer is laminated forms a plate shape having an aspect ratio of 1/200 or less, which is the ratio of the short axis length to the major axis length based on the vertical section. It includes;

According to a preferred embodiment of the present invention, the mold distribution plate may have the same diameter or cross-sectional area of the island component prison holes forming the same layer with the island component supply paths forming a plurality of layers.

According to another preferred embodiment of the present invention, the mold distribution plate may have the same diameter or cross-sectional area of the island component prison holes forming the same layer with the island component supply paths forming a plurality of layers.

According to another preferred embodiment of the present invention, the diameter or cross-sectional area of the island-containing detent holes forming different layers may be different.

According to another preferred embodiment of the present invention, a plurality of layers having the same diameter or cross-sectional area of the conductive element detention holes included therein are formed, the plurality of layers form a group, and the plurality of groups may be formed. Can be.

According to another preferred embodiment of the present invention, the group may be three, more preferably the group may be four or more.

According to another preferred embodiment of the present invention, the aspect ratio of the plate-shaped in the step (4) is 1/300 or less, preferably 1/500 or less, more preferably 1/1000 or less, more preferably 1 / 2000 or less, more preferably 1/3000 or less, more preferably 1/5000 or less, still more preferably 1/10000 or less, most preferably 1/20000 or less.

According to another preferred embodiment of the present invention, the first component is 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), 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), melanin (MF), unsaturated polyester (UP), silicone (SI) and cycloolefin polymer may be any one or more selected from the group consisting of.

According to another preferred embodiment of the present invention, the second component is 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), 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), melanin (MF), unsaturated polyester (UP), silicone (SI) and cycloolefin polymer may be any one or more selected from the group consisting of.

According to another preferred embodiment of the present invention, the skin layer component is 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), 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), melanin (MF), unsaturated polyester (UP), silicone (SI) and cycloolefin polymer can be any one or more selected from the group consisting of.

According to another preferred embodiment of the present invention, between the steps (1) and (2), the first component transferred from the extrusion unit is discharged into the island-in-the-sea extrusion mold through the first pressing means. It may further include.

According to another preferred embodiment of the present invention, between the steps (1) and (2), the second component transferred from the extrusion unit is discharged to the island-in-the-sea extrusion mold through the second pressing means It may further include.

According to another preferred embodiment of the present invention, the island component detention holes of the detention distribution plate included in the island-like extrusion mold may be arranged in a zigzag.

According to another preferred embodiment of the present invention, at least one or more of the diameter and the cross-sectional area of the island-shaped detention hole of the detention distribution plate included in the island-like extrusion mold may be different.

According to another preferred embodiment of the present invention, the flow control unit may be a T-die or a coat-hanger die.

According to another preferred embodiment of the present invention, after the step (4), it may include the step of stretching the reflective polarizer in which the polymer is dispersed.

According to another preferred embodiment of the present invention, after the stretching step, the aspect ratio of the plate-shaped is 1/1000 or less, preferably 1/2000 or less, preferably 1/3000 or less, preferably 1/5000 or less, It may be preferably 1/10000 or less, more preferably 1/20000 or less, more preferably 1/30000 or less, even more preferably 1/50000 or less, and most preferably 1/70000 or less.

According to still another preferred embodiment of the present invention, an apparatus for manufacturing a reflective polarizer in which a polymer of the present invention is dispersed may include a core layer having a plurality of first components dispersed therein and at least one surface of the core layer. An apparatus for manufacturing a reflective polarizer in which a polymer including a formed skin layer is dispersed, the apparatus comprising: three or more extruded portions into which a first component, a second component, and a skin layer component are separately added; In order to form an island-in-the-sea composite type in which the first component is dispersed inside the second component, and the island-in-the-sea composite type reflects the shear wave (S wave) of a desired wavelength, the first component is dispersed in the second component. In order to form an island-in-the-sea composite flow, and the island-in-the-sea composite flow may reflect the transverse wave (S wave) of a desired wavelength, the first component and the first component transferred from the extruded portion to which the first component is injected and the extruded portion to which the second component is injected, A spin block portion including an island-in-the-sea type extrusion mold including a plurality of mold distribution plates, in which part or all of the diameter or the cross-sectional area of the island-based supply paths forming the island-in-the-sea composite flow by inputting two components; A feed block portion in communication with the extruder into which the skin layer component is injected, for laminating the skin layer on at least one surface of the island-in-the-sea composite products transferred from the spin block portion; And a flow control unit for inducing spreading of the first component of the island-in-the-sea composite compound in which the skin layer transferred from the feed block unit is laminated to form a plate shape based on a vertical section.

According to another preferred embodiment of the present invention, the plate-shaped aspect ratio is the ratio of the short axis length to the long axis length relative to the vertical section is 1/200 or less, 1/300 or less, preferably 1/500 or less, more preferably Preferably it is 1/1000 or less, More preferably, it is 1/2000 or less, More preferably, it is 1/3000 or less, More preferably, it is 1/5000 or less, More preferably, it is 1/10000 or less, Most preferably 1/20000 It may be

According to another preferred embodiment of the present invention, the number of layers of the island component supply passages of the distribution plate included in the island-like extrusion mold is 100 or more, preferably 200 or more, more preferably 400 or more, More preferably 600 or more.

According to another preferred embodiment of the present invention, any one or more of the cross-sectional area or diameter of the island component supply paths of the mold distribution plate included in the island-in-the-sea extrusion mold may be different.

According to another preferred embodiment of the present invention, the spin block portion may include a first pressurizing means for discharging the first component transferred from the extrusion unit to supply to the island-in-the-sea extrusion mold.

According to another preferred embodiment of the present invention, the spin block portion may include a second pressurizing means for discharging the second component transferred from the extrusion unit to supply to the island-in-the-sea extrusion mold.

According to another preferred embodiment of the present invention, the flow control unit may be a T-die or a coat-hanger die.

Hereinafter, terms used in this specification will be briefly described.

'Polymer has birefringence' means that when light is irradiated to fibers of different refractive index along the direction, the light incident on the polymer is refracted into two light beams with different directions.

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

'Anisotropy' means that the optical properties of an object are different according to the direction of light, and anisotropic objects have birefringence and correspond to isotropy.

'Light modulation' means that the irradiated light reflects, refracts, scatters, changes the intensity of the light, the period of the wave or the nature of the light.

The 'aspect ratio' means the ratio of the shortening length to the longest length based on the vertical section in the longitudinal direction of the elongated body.

The reflective polarizer manufactured by the manufacturing method of the present invention has a plate-like polymer in the substrate, and thus includes a very small number of birefringent polymers in the same area compared to the reflective polarizer including the conventional birefringent polymer. Not only can it achieve very good optical properties, but also have a plate-like polymer having various optical thicknesses, which is very advantageous to cover the entire visible light region.

In addition, since the skin layer is formed on at least one surface of the core layer in the molten state, it does not go through a separate bonding step. This makes it possible to remarkably reduce the manufacturing cost and to maximize optical properties at a limited thickness.

1 is a schematic view for explaining the principle of a conventional reflective polarizer.
2 is a perspective view of a reflective polarizer comprising a rod-shaped polymer.
3 is a cross-sectional view showing a path of light incident on a birefringent island-in-the-sea yarn used in a reflective polarizer.
4 and 5 are perspective views showing the coupling structure of the distribution plate of the sea-island extrusion mold that can be used in the present invention.
6 is a cross-sectional view of the distribution plate according to another preferred embodiment of the present invention.
7 and 8 are cross-sectional views showing in detail the arrangement of the island component supply passage (detention hole) of the detention distribution plate according to the preferred embodiment of the present invention.
9 and 10 are perspective views showing the coupling structure of the distribution plate of the sea-island type extrusion mold that can be used in the present invention.
11 is a schematic view including a first pressurizing means to form an island-in-the-sea composite flow according to a preferred embodiment of the present invention.
12 is a schematic view including a second pressurizing means for forming an island-in-the-sea composite flow according to a preferred embodiment of the present invention.
13 is a cross-sectional view of a coat-hanger die according to one preferred embodiment of the present invention, and FIG. 14 is a side view.
15 is a cross-sectional view of a reflective polarizer according to an exemplary embodiment of the present invention.
16 is a cross-sectional view of a reflective polarizer according to another exemplary embodiment of the present invention.
17 is a perspective view of a reflective polarizer according to an exemplary embodiment of the present invention.
18 is a cross-sectional view of a plate-like polymer according to an embodiment of the present invention.
19 is a cross-sectional view of a plate-like polymer according to another preferred embodiment of the present invention.
20 is a schematic diagram of an apparatus for manufacturing a reflective polarizer in which a polymer is dispersed according to a preferred embodiment of the present invention.
21 is a schematic diagram of an apparatus for manufacturing a reflective polarizer in which a polymer is dispersed according to another exemplary embodiment of the present invention.
22 is an exploded perspective view of a liquid crystal display device including the reflective polarizer of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS The invention will be described in more detail with reference to the accompanying drawings.

As described above, the reflective polarizer including the birefringent polymer in the conventional substrate has significantly lower optical properties than the stacked reflective polarizer, and there is a problem in that too many birefringent polymers must be disposed in the substrate to improve this. . Furthermore, the core layer and the skin layer are separately manufactured and laminated through the adhesive layer, thereby not only significantly increasing the cost but also reducing the thickness of the core layer, thereby reducing optical properties and significantly increasing the defective rate.

Accordingly, a method of manufacturing a reflective polarizer in which a polymer of the present invention is dispersed includes a reflective polarizer in which a polymer including a core layer having a plurality of first components dispersed therein and a skin layer formed on at least one surface of the core layer. 1. A method of manufacturing a method comprising the steps of: (1) supplying a first component, a second component and a skin layer component to the extruders, respectively; (2) forming an island-in-the-sea composite compound in which a plurality of first components are dispersed inside the second component, wherein the island-in-the-sea composite compound reflects an S wave of a desired wavelength and forms an optical thickness of the first components differently. To this end, the island-in-the-sea composites are prepared by injecting the first component and the second component transferred from the extruder into a single island-in-the-sea type extrusion mold including part or all of different diameter or cross-sectional areas of the island component feed passages. Forming (3) laminating at least one surface of the island-in-the-sea composites with the skin layer component transferred from the extrusion unit; And (4) inducing spreading in the flow control unit such that the first component of the island-in-the-sea composite compound in which the skin layer is laminated forms a plate shape having an aspect ratio of 1/200 or less, which is the ratio of the short axis length to the major axis length based on the vertical section. The above-mentioned problem was sought, including; As a result, in the case of including a very small number of birefringent polymers with respect to the same area as compared to the reflective polarizer including the conventional birefringent polymer, it is possible to achieve very good optical properties and to have a plate-like polymer having various optical thicknesses. It is very advantageous to cover the entire visible light area. In addition, since the skin layer is formed on at least one surface of the core layer in the molten state, it does not go through a separate bonding step. This makes it possible to remarkably reduce the manufacturing cost and to maximize optical properties at a limited thickness.

First, in step (1), the first component, the second component, and the skin layer component are supplied to the extruding portions, respectively. The first component may be used without limitation as long as the polymer is dispersed in the second component forming the substrate and used in a reflective polarizer in which a conventional polymer is dispersed. Preferably, polyethylene naphthalate (PEN), copolyethylene or Phthalate (co-PEN), Polyethylene terephthalate (PET), Polycarbonate (PC), Polycarbonate (PC) alloy, Polystyrene (PS), Heat-resistant polystyrene (PS), Polymethylmethacrylate (PMMA), Polybutyl Rent Terephthalate (PBT), Polypropylene (PP), Polyethylene (PE), Acrylonitrile Butadiene Styrene (ABS), Polyurethane (PU), Polyimide (PI), Polyvinyl Chloride (PVC), Styrene Acrylic Nitrile Blend (SAN), Ethylene Vinyl Acetate (EVA), Polyamide (PA), Polyacetal (POM), Phenolic, Epoxy (EP), Urea (UF), Melanin (MF), Unsaturated Polyester (UP), Silicone (SI) and cycloolefin polymers are used Number and may be more preferably PEN.

The second component may be used without limitation as long as the second component is used as a material of the substrate in the reflective polarizer in which the polymer is dispersed. Preferably, the polyethylene naphthalate (PEN) and the copolyethylene naphthalate (co-PEN) are used. ), 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), melanin (MF), unsaturated polyester (UP), silicone (SI) and cyclic Alone or mixed with a low-olefin polymer And dimethyl-2,6-naphthalene dicarboxylate, dimethylterephthalate and monomers such as ethylene glycol and cyclohexanedimethanol (CHDM) may be suitably polymerized co-PEN.

The skin layer component can be used without limitation as long as it is usually used in a reflective polarizer in which a polymer is dispersed. Preferably, the skin layer component may be a polyethylene terephthalate (PET), a polycarbonate (PC), a polycarbonate (PC) ), Heat resistant polystyrene (PS), polymethyl methacrylate (PMMA), polybutylene terephthalate (PBT), polypropylene (PP), polyethylene (PE), acrylonitrile butadiene styrene (ABS), polyurethane ), Polyimide (PI), polyvinyl chloride (PVC), styrene acrylonitrile blend (SAN), ethylene vinyl acetate (EVA), polyamide (PA), polyacetal (POM) (UF), melamine (MF), unsaturated polyesters (UP), silicon (SI) and cycloolefin polymers. The polycarbonate alloy is preferably made of a polycarbonate and a modified glycol polycyclohexylene dimethylene terephthalate (PCTG), more preferably a polycarbonate and a modified glycol polycyclohexane (PCTG) may be a polycarbonate alloy having a weight ratio of 5:95 to 95: 5. In the meantime, the skin layer of the present invention is preferably made of a material having a small change in refractive index in the spreading and stretching process, more preferably polycarbonate or polycarbonate glass.

Meanwhile, the first component, the second component, and the skin layer component may be separately supplied to the independent extrusion units. In this case, the extrusion unit may be composed of three or more. In addition, it is also included in the scope of the present invention because it is interpreted as a plurality of extruded parts to supply a separate feed passage and the distribution port so that the polymer is not mixed. The extruder may be an extruder, which may further include a heating means or the like to convert the supplied polymers in the solid phase into a liquid phase.

Next, in step (2), in order to form a island-in-the-sea composite flow in which a plurality of first components are dispersed within the second component, and the island-in-the-sea composite flow reflects the shear wave (S wave) of a desired wavelength, the extrusion portion The first component and the second component transferred from the single islands-in-the-sea type extrusion mold are input to form a single island-in-the-sea composite flow.

Specifically, Figures 4 and 5 is a perspective view showing a coupling structure of the distribution plate of the island-in-the-sea extrusion extrusion mold that can be used in the present invention. The first mold distribution plate S1 positioned at the upper end of the island-in-the-sea extrusion mold may include a first component supply passage 50 and a second component supply passage 51 therein. So that the first component transferred through the extrusion portion can be supplied to the first component supply path 50 and the second component can be supplied to the second supply path 51. A plurality of such supply paths may be formed as the case may be. Polymers that have passed through the first receiving distribution plate S1 are transported to the second receiving distribution plate S2 located below. The first component introduced through the first component supply path 50 is branched and transferred to the plurality of first component supply paths 52 and 53 along the flow path. In addition, the second component introduced through the second component supply path 51 is branched to the plurality of second component supply paths 54, 55, and 56 along the flow path, and is transported. The polymers passing through the second separating distribution plate S2 are transported to the third separating distribution plate S3 located below. The first component introduced through the first component supply paths 52 and 53 is branched along the flow path to the first component supply paths 59, 60, 63, and 64 formed in the third prison distribution plate S3, respectively. Transferred. Similarly, the second components introduced through the second component supply paths 54, 55, 56 are second component supply paths 57, 58, 61, 62, 65, 66 formed in the third detention distribution plate S3, respectively. Branched along the flow path. The polymers that have passed through the third separation distribution plate S3 are transferred to the fourth separation distribution plate S4 located below. The first components injected through the first component supply paths 59, 60, 63 and 64 are respectively spread over the first component supply paths 69 formed in the fourth separate distribution plate S4, The second component introduced through the component supply paths 57, 58, 61, 62, 65 and 66 is connected to the second component supply passages 67 and 68 formed at the upper and lower ends of the first component supply passages 69 along the flow path. ). At this time, the number of layers of the first component included in the sea-island complex flow is determined by the number of vertical layers (n) of the first component supply paths 69. For example, when the number of longitudinal direction layers is 50, the number of layers of the first component included in the first isolar compound current is 50. [ The number of the island component layers in the fourth mold distribution plate S4 is 25 or more, more preferably 50 or more, more preferably 100 or more, more preferably 200 or more, even more preferably 400 In the above, most preferably, 600 or more. Thereafter, in the fifth separating plate S5, the first component seeps between the dispersed first components to form a sea-island complex stream in which the first component is dispersed in the second component, and then the sea- And discharged through the discharge port 70 of the sixth housing distribution plate S6. Meanwhile, FIGS. 4 and 5 are examples of islands-in-the-sea detention distribution plates that can be used in the present invention, and the number, structure, and detention of detention distribution plates for manufacturing island-in-the-sea composites in which the first component is dispersed in the second component. It is obvious to those skilled in the art to appropriately design and use the size, shape and the like of the holes. Preferably, the diameter of the through-hole of the isometric-supply path may be 0.17 to 5 mm, but is not limited thereto.

Meanwhile, as the number of layers of the island component supply path in the fourth mold distribution plate S4 increases, a degree of conduction may occur between the island components (first component). In order to prevent this, the island component supply passage may be partitioned as shown in FIG. 6, and sea component supply passages 71 and 72 may be formed on the partition passage so that the sea component may penetrate smoothly between the island components. As a result, even if the number of layers in the island component supply path increases, the degree of conduction between the island components (the first component) included in the final substrate may be minimized.

FIG. 7 illustrates an arrangement of island component supply paths that may be included in the fourth mold distribution plate, and the diameters of the island component supply paths forming the same layer L1 are the same. Meanwhile, similarly, the diameters of the island component supply paths forming another layer L2 and the diameters of the island component supply paths forming another layer L3 are the same. On the other hand, the diameter (a) of the island component supply path of L1, the diameter b of the island component supply path of L2, and the diameter (c) of the island component supply path of L3 are in the order of b> c> a, This arrangement of layers can be repeated randomly or randomly. Reflective polarizer manufactured through this can form the optical thickness of the plate-shaped polymer contained therein differently for each layer is very advantageous to achieve a wide range of light modulation.

FIG. 8 illustrates an arrangement of island component supply paths that may be included in a fourth detaining distribution plate according to another exemplary embodiment of the present invention, which will be described with reference to FIG. 7. Specifically, layers having the same diameter of the island component supply passages are gathered to form four groups 81, 82, 83, and 84. In this case, the diameter or cross-sectional area of the island component supply paths included in the same group may be substantially the same, but the diameter or cross-sectional area of the island component supply paths included in the different group may be different from each other. In this case, the cross-sectional areas of the island component supply paths included in each of the groups 81, 82, 83, and 84 may be arranged in the order of b>c>d> a. In addition, the number of layers forming one group may be 100 or more, preferably 200 or more. The reflective polarizer manufactured through this process can minimize the agglomeration of polymers because plate-shaped polymers having different optical thicknesses and aspect ratios are formed by aligning a plurality of groups. In addition, since the component feed paths are arranged in a zigzag pattern, light leakage can be minimized through this.

9 and 10 are diagrams of the detention of the island-in-the-sea extrusion mold according to a preferred embodiment of the present invention. Specifically, there are six detention distribution plates of the island-in-the-sea reflective reflector, which are different from the detention distribution plate of FIG. 4 in the fourth detention distribution plate T4 and the fifth detention distribution plate T5. Referring to the difference from FIG. 4, the fourth detention distribution plate T4 of FIG. 9 includes a second component supply passage between the first component supply passage aggregation units 100, 101, and 102 similarly to FIG. 6. It is divided into a flow path. Thereby allowing the second component to evenly penetrate between the first components.

On the other hand, it is also possible to form an island-in-the-sea composite flow through the fourth detention distribution plate T4 and the fifth detention distribution plate T5 of FIG. 9. In other words, a separate sea-island complex flow is formed through the partitioned distribution ducts 100, 101, 102 of the fourth separation distribution plate T4 and three sea-like complex flows are formed in the interior After that, you can join together again. For this purpose, the design and modification of a separate distribution plate is obvious to a person skilled in the art, and is included in a plurality of integrated seawater extrusion apparatuses.

On the other hand, the island-in-the-sea composites may have different optical thicknesses of the first component dispersed inside the second component to cover the wavelength range of the different light. To this end, the diameter, cross-sectional area, shape, and / or number of layers of the island component supply passage and / or the sea component supply passage included in the same island-in-the-sea extrusion mold may be different. Through this, the reflective polarizer manufactured through the spreading and stretching process may have various optical thicknesses in which the plate-shaped polymers formed therein are very advantageous to include the entire visible light region.

More specifically, the optical thickness means n (refractive index) x d (physical thickness). Therefore, the optical thickness of the first component included in the island-in-the-sea composites can be varied by differently adjusting the cross-sectional area, diameter, etc. of the seam-type extrusion hole. It is possible to reflect S waves in the wavelength range of light and transmit P waves.

More specifically, the wavelength and optical thickness of the light is defined according to the following relational formula (1).

[Relation 1]

λ = 4nd

Where? Is the wavelength of light (nm), n is the refractive index, d is the physical thickness (nm)

Therefore, when the optical thickness (nd) deviates, it is possible to cover not only the wavelength of the target light but also the wavelength range of the light including the target, thereby greatly improving uniform optical properties. The above-described deviation of the optical thickness can be achieved by giving a deviation in diameter, cross-sectional area, etc. from one island-in-the-sea extrusion mold to the island component supply passage.

According to another preferred embodiment of the present invention, the first component transferred from the extruder between the steps (1) and (2) is discharged into different islands-in-sea type extrusion molds through the first pressing means. It may further include. Specifically, FIG. 11 is a schematic view including a first pressurizing means, wherein a first component conveyed from an extruder (not shown) is supplied to the first pressurizing means 130 and a sea island type through the first pressurizing means 130. It may be supplied to the extrusion mold 132. To this end, the discharge amount of the first pressing means 130 may be 1 ~ 100 kg / hr, but is not limited thereto.

Similarly, the second component transferred from the extruder may further include a step of discharging the different island-in-the-sea extrusion molds through the second pressing means. Specifically, Figure 12 is a schematic diagram including a second pressing means, the second component conveyed from the extrusion unit (not shown) is supplied to the second pressing means 140 and the island-in-the-sea type through the second pressing means 140 It may be supplied to the extrusion mold 142. To this end, the discharge amount of the second pressing means 130 may be 1 ~ 100 kg / hr, but is not limited thereto.

Next, as a step (3), the skin layer component transferred from the extruded part is laminated on at least one surface of the core layer (sea-island composites). Preferably, the skin layer component may be laminated on both surfaces of the core layer. When the skin layer is laminated on both surfaces, the material and the thickness of the skin layer may be the same or different from each other. On the other hand, the place of the core layer and the skin layer is also included in the separate place or performed simultaneously in the place of step (2).

Next, in step (4), the first component of the core layer on which the skin layer is laminated induces spreading in the flow control unit so as to form a plate shape. Specifically, FIG. 13 is a cross-sectional view of a coat-hanger die, which is a kind of preferred flow control unit that may be applied to the present invention, and FIG. 14 is a side view. Accordingly, the degree of spreading of the core layer can be appropriately adjusted so that the vertical cross section of the first component in the longitudinal direction can be adjusted to have a plate-like shape. In FIG. 13, since the core layer in which the skin layer transferred through the flow path is laminated spreads widely from side to side in the coat-hanger die, the first component included therein also spreads from side to side. In addition, as shown in the side view of Figure 14, the coat hanger die is wide spread from side to side but has a structure that is reduced up and down, so that the skin layer is spread in the horizontal direction of the laminated core layer or reduced in the thickness direction. This is based on Pascal's principle, in which the fluid in the enclosure is guided to spread widely in the width direction by the principle that the pressure is transmitted to the fine portion by a certain pressure. Therefore, the outlet size is wider in the width direction than the die inlet size, and the thickness is reduced. This requires the use of the Pascal principle in which the molten liquid material can flow and shape controlled by pressure in a closed system, preferably a polymer flow rate and viscosity induction such that a flow of laminar flow of less than 2,500 Reynolds numbers is preferred. When the flow of the turbulent flow is 2,500 or more, the induction of the plate-like type becomes uneven, and there is a possibility that the optical characteristic is varied. The left and right die width of the outlet of the coat-hanger die may be between 800 and 2,500 mm and the fluid flow of the polymer is required to regulate the pressure so that the Reynolds number does not exceed 2,500. The reason is that the polymer flow becomes turbulent and the arrangement of the cores may be disturbed. Also, the internal temperature may be 265 to 310 ° C. On the other hand, the degree of spreading may be influenced by the compatibility of the first component and the second component, and in order to have excellent spreadability, PEN as the first component and CO-PEN as the second component may be used. Further, the degree of spreading can be controlled by appropriately polymerizing monomers constituting CO-PEN, for example, dimethyl-2,6-naphthalene dicarboxylate, dimethyl terephthalate, ethylene glycol and cyclohexane dimethanol (CHDM) have. The flow control part may be a T-die or a manifold type Coat-hanger die so that the first component can form a plate-like shape. However, the present invention is not limited to this, and it is possible to induce the spreading of the core layer to induce the first component into a plate- Anything that can be used can be used without limitation.

On the other hand, the plate-like shape has an aspect ratio of 1/200 or less, 1/300 or less, or 1/500 or less, which is the ratio of the minor axis length to the major axis length, 1/1000 or less, 1/2000 or less, 1/5000 or less, 1/10000 or less, or 1/20000 or less. If the aspect ratio is more than 1/200, it is difficult to achieve the desired optical properties even if the aspect ratio is reduced through the elongation of the polarizer thereafter. In particular, when the aspect ratio of the first component is adjusted by controlling the aspect ratio of the final first component through induction of spreading with an aspect ratio exceeding 1/200 and then by a high draw ratio of 6 times or more, the area of the first component is smaller than the area of the second component, Due to the light leakage phenomenon, there is a problem of deterioration of optical characteristics.

As a result, the smaller the ratio of the minor axis length to the major axis length is, the more desirable the desired optical properties can be attained even if a smaller number of the plate-like polymer is contained in the substrate.

According to a preferred embodiment of the present invention, after the step (4), it may further include the step of stretching the reflective polarizer, and more specifically (5) cooling the polarizer induced the spread induced in the flow control unit And smoothing; (6) stretching the polarizers subjected to the smoothing; And (7) heat setting the stretched polarizer.

First, as a step (5), cooling and smoothing of the polarizer transferred from the flow control unit may be performed by cooling used in the manufacture of a conventional reflective polarizer to solidify it, and then may be performed through a casting roll process or the like.

Thereafter, a step of stretching the polarizer through the smoothing step is performed. The stretching may be effected through a conventional process of stretching the reflective polarizer, thereby causing a refractive index difference between the first component and the second component to cause a light modulation phenomenon at the interface, and the spreading induced first component The aspect ratio is further reduced through stretching. Therefore, in order to adjust the optical thickness by deriving the desired aspect ratio of the plate-like first component in the final reflective polarizer, the optical thickness can be appropriately set in consideration of the diameter of the island component supply path, the spreading inducing condition, will be. For this purpose, the uniaxial stretching or biaxial stretching can be preferably performed in the stretching step, and more preferably uniaxial stretching can be performed. In the case of uniaxial stretching, the stretching direction may be performed in the longitudinal direction of the first component. The stretching ratio may be 3 to 12 times. On the other hand, a method of changing an isotropic material to birefringent is commonly known. For example, when stretching under appropriate temperature conditions, polymer molecules may be oriented so that the material becomes birefringent.

Next, the final reflective polarizer may be manufactured by performing heat setting of the stretched polarizer as step (7). The heat setting may be heat setting through a conventional method, preferably may be carried out through an IR heater, a ceramic heater, hot air heater and the like at 180 ~ 200 ℃ for 0.1 to 3 minutes. On the other hand, if the optical thickness and aspect ratio to be targeted in the present invention is determined, the reflective polarizer of the present invention is manufactured by appropriately controlling the specifications of the island-in-the-sea extrusion mold, the discharge amount of the pressurizing means, the specification and the draw ratio of the flow control unit, and the like. You can do it.

The reflective polarizer in which the polymer prepared by the above-described method is dispersed has a core layer and a skin layer formed on at least one surface of the core layer, and transmits the first polarized light irradiated from the outside and reflects the second polarized light. The core layer includes a plurality of polymers dispersed within a substrate (a plurality of discontinuous phases dispersed within a continuous phase), wherein the plurality of polymers have a refractive index different from the substrate in at least one axial direction, and the plurality of polymers An optical modulation interface is formed between the polymer and the substrate, and includes a polymer having an aspect ratio of 1/1000 or less, which is a ratio of the short axis length to the long axis length based on the vertical section of the polarizer. In addition, the core layer and the skin layer are integrally formed and do not include an adhesive layer.

Specifically, FIG. 15 is a cross-sectional view of a reflective polarizer according to an exemplary embodiment of the present invention, wherein skin layers 181 and 182 are formed on both surfaces of the core layer 180, and the inside of the core layer 180 is formed. A plurality of polymers 183, 184, 185, 186 are dispersed. In this case, the dispersed polymers 183, 184, 185, and 186 may have a plate shape having an aspect ratio of 1/1000 or less, which is a ratio of the short axis length to the long axis length based on the vertical cross section in the longitudinal direction of the polymer. The polymer may have an appropriate optical thickness to reflect the desired wavelength of light (S wave) and may have a thickness deviation within an appropriate range.

 In this case, the optical thickness means n (refractive index) x d (physical thickness). On the other hand, the wavelength of light and the optical thickness are defined by the following relational expression (1).

[Relation 1]

λ = 4nd

Where? Is the wavelength of light (nm), n is the refractive index, d is the physical thickness (nm)

Therefore, if the average optical thickness of the polymers is 150nm, it is possible to reflect the transverse wave (S wave) of the 400nm wavelength by the relation (1). In this case, if the thickness variation is 30%, the wavelength band may cover approximately 420 nm to 780 nm. In addition, when the plate-like polymer, which is the first component, has optical birefringence, P waves must be transmitted and S waves must be reflected, so that the refractive index n is set based on the thickness direction (z-axis refractive index) through which light passes, and the average optical thickness is calculated. can do. Therefore, preferably, the optical thickness of the polymers may be 1/3 to 1/5 of the desired light wavelength λ.

On the other hand, the plate-shaped polymer dispersed in the core layer to form a plurality of layers having a space between each other. In this case, the number of layers formed by the plate-like polymers in one group may be 100 or more, preferably 150 or more, more preferably 200 or more, more preferably 400 or more, most preferably 600 Can be more than. Also, polymers forming the adjacent layers may be zigzag like in FIG. 15 to maximize the light modulation effect.

On the other hand, in order to improve the light modulation effect, the average distance d ₁ of adjacent polymers forming the same layer may be smaller than the average distance d ₂ of inscribed polymers forming different layers. This minimizes the distance between polymers forming the same layer, thereby reducing light leakage and maximizing the light modulation effect.

According to a preferred embodiment of the present invention, the core layer and the skin layer are integrally formed. As a result, deterioration of optical properties due to the adhesive layer can be prevented, and more layers can be added to a limited thickness, so that optical properties can be remarkably improved. Further, since the skin layer is produced simultaneously with the core layer and then the stretching process is performed, unlike the conventional adhesion of the core layer after stretching to the unstretched skin layer, the skin layer of the present invention can be stretched in at least one axial direction. As a result, the surface hardness is improved as compared with the non-drawn skin layer, and the scratch resistance is improved and the heat resistance can be improved.

16 is a cross-sectional view of a reflective polarizer according to another exemplary embodiment of the present invention. This will be described based on the difference from FIG. 15, wherein polymers having different average optical thicknesses are arranged in groups within the core layer, which can be achieved through the above-described detaining plate of FIG. 8. Through this, it is possible to cover various optical wavelength bands, which can reflect the S-waves in the entire visible light region and minimize the problem of polymer bonding.

FIG. 17 is a perspective view of a reflective polarizer according to an exemplary embodiment of the present invention, in which a plurality of polymers 211 are elongated in a length direction in a second polymer 210 and the cross-sectional shape is a plate shape. Skin layers 212 and 213 are formed on both sides of the second polymer 210. In this case, each of the plate-like polymers 211 can be elongated in various directions, but it is preferable to elongate them in parallel in any one direction, more preferably, in a direction perpendicular to the light irradiated from the external light source, Is effective in maximizing the light modulation effect.

According to a preferred embodiment of the present invention, the aspect ratio whose vertical cross section in the longitudinal direction of the polymer is the short axis length with respect to the long axis length is 1/1000 or less. 18 is a vertical cross section in the longitudinal direction of a plate-like polymer that can be used in the present invention, wherein the ratio of the relative length of the major axis length (a) and the minor axis length (b) when the major axis length is a and the minor axis length is b (aspect ratio) ) Should be less than 1/1000. In other words, when the major axis length (a) is 1000, the minor axis length (b) should be less than or equal to 1, which is 1/1000. If the ratio of the minor axis length to the major axis length is larger than 1/1000, it is difficult to achieve the desired optical properties. The aspect ratio can be appropriately adjusted through spreading induction and stretching of the first component during the above-described manufacturing steps. On the other hand, although the cross section of the polymer is shown as a ratio of the short axis length to the long axis length is greater than 1/1000 in the drawings of the present invention, this is only a problem of the method represented in the drawings for the sake of understanding, in practice Compared with the polymer, the long axis direction is longer and the short axis direction is shorter.

More specifically, when the display is based on the vertical cross-section of the reflective polarizer 32 inches and applied to 1580 mm and 400 μm in height, the conventional reflective polarizer may include 100 million or more birefringent polymers to achieve desired optical properties. . In contrast, the reflective polarizer of the present invention can achieve an optical property that the transmittance of the reflective polarizer in the transmission axis direction is 90% or more and the transmittance in the reflective axis direction is 30% or less even when the number of the plate- More preferably, the optical transmittance in the transmission axis direction is not less than 87% and the transmittance in the reflection axis direction is not more than 10%, and most preferably, the transmittance transmittance is not less than 85% The transmittance may be 7% or less. In this case, preferably, the reflection type polarizer of the present invention may contain not more than 500,000 of the above-mentioned plate-like polymer, and most preferably not more than 300,000 of the above-mentioned plate-like polymer. To this end, according to a preferred embodiment of the present invention, the ratio of the short axis length to the long axis length of the polymer is preferably 1/1000 or less, more preferably 1/1500 or less, even more preferably 1/2000 or less, further Preferably less than 1/3000, more preferably less than 1/5000, more preferably less than 1/10000 or less than 1/20000, more preferably less than 1/30000, more preferably less than 1/50000, most Preferably, it may be 1/70000 to 1/200000.

As a result, the smaller the ratio of the minor axis length to the major axis length is, the more desirable the desired optical properties can be attained even if a smaller number of the plate-like polymer is contained in the substrate.

However, when the aspect ratio of the plate-like polymer becomes very small, the spacing space between the plate-like plane forming polymers forming the same layer can be extremely small. However, in the reflection type polarizer of the present invention, at least one spacing space necessarily exists between the plate-like polymers forming the same layer.

According to a preferred embodiment of the present invention, the reflective polarizer comprises a plurality of plate-shaped polymers satisfying the above-mentioned aspect ratio condition among all the plate-like polymers contained in the substrate, , Preferably not less than 60%, more preferably not less than 70%, more preferably not less than 80%, and most preferably not less than 90%.

According to a preferred embodiment of the present invention, a birefringent interface may be formed between the plate-like polymer (first component) and the substrate (second component) forming the core layer. Specifically, in a reflection type polarizing element including a polymer in a substrate, the magnitude of the substantial agreement or inconsistency of the refractive index along the X, Y, and Z axes in space between the substrate and the plate-like polymer depends on the scattering degree of the polarized light ray along the axis . Generally, the scattering ability changes in proportion to the square of the refractive index mismatch. Thus, the greater the degree of discrepancy in refractive index along a particular axis, the more scattered light rays are polarized along that axis. Conversely, when the inconsistency along a particular axis is small, the polarized light rays along the axis are scattered to a lesser degree. If the refractive index of the substrate along an axis is substantially coincident with the refractive index of the sheet-like polymer, the incident light polarized with an electric field parallel to this axis will pass through the polymer without scattering, regardless of the size, shape and density of the portion of the polymer . Also, when the refractive index along the axis is substantially coincident, the light rays pass through the object without being substantially scattered. More specifically, the first polarized light (P wave) is transmitted without being influenced by the birefringent interface formed at the interface between the base and the polymer, while the second polarized light (S wave) is transmitted through the birefringent interface Modulation of light is affected by this effect. As a result, the P wave is transmitted and the S wave is modulated by light such as scattering and reflection of light, resulting in separation of polarized light.

Therefore, when the substrate is optically isotropic, the plate-like polymer may have birefringence, and conversely, when the substrate is optically birefringent, the plate-like polymer may have birefringence The polymer may have optical isotropy. Specifically, when the refractive index of the polymer in the x-axis direction 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 index of the base is nX2, nY2 and nZ2, Can occur. More preferably, at least one of the X, Y, and Z axis refractive indexes of the substrate and the polymer may be different, and more preferably, when the elongation axis is the X axis, the difference in refractive index between the Y axis and the Z axis direction is 0.05 or less , And the difference in refractive index with respect to the X-axis direction may be 0.1 or more. On the other hand, when the difference in the refractive index is 0.05 or less, it is interpreted as matching.

On the other hand, according to a preferred embodiment of the present invention, the total number of layers of the plate-shaped polymer may be 50 to 3000, the plate-shaped polymer forming one layer is 30 to 1,000, the layer spacing between each layer is 0.001 ~ 1.0 μm. In addition, the separation distance between adjacent plate-shaped polymer forming one layer may be up to 0.001 ~ 1.0㎛. In addition, the short axis length of the vertical cross section of the plate-like polymer in the longitudinal direction may be 0.01 to 1.0 탆, and the long axis length of the vertical cross section of the elongate in the length direction may be 100 to 17,000 탆. Meanwhile, the layer spacing, the number of layers, the spacing distance, the short axis length, etc. of the present invention can be appropriately adjusted according to the aspect ratio and the desired wavelength of light of the present invention.

Meanwhile, in the present invention, the thickness of the core layer is 20 to 180 μm, and the thickness of the skin layer may be 50 to 300 μm, but is not limited thereto.

According to a preferred embodiment of the present invention, the polymer may be coated with a third material or further include other materials inside the polymer. Specifically, FIG. 19 may further include a third material 191 such as filler, metal particles, polymer, etc. in the polymer 190 as a cross section of the polymer according to an exemplary embodiment of the present invention. In this case, the included third material 191 may have a different refractive index to form a birefringent interface with the polymer. For example, when the optical property of the polymer 190 is birefringent, the third material 191 may have optical isotropy to form a birefringent interface with the polymer 190. Meanwhile, the third material 191 may also be an elongate body that extends in the longitudinal direction of the polymer. Further, even when the polymer is coated with the third material, the third material may be formed at the birefringence interface between the substrate and / or the polymer and the coated third material as in the case of including the third material inside the polymer. The refractive index of the material can be adjusted appropriately.

According to an exemplary embodiment of the present invention, an apparatus for manufacturing a reflective polarizer in which a polymer is dispersed includes a core layer having a plurality of first components dispersed therein and a skin layer formed on at least one surface of the core layer. The three or more extrusion parts into which the first component, the second component, and the skin layer component are separately input, and the composite flow, have a first component inside the second component so as to reflect the shear wave (S wave) of a desired wavelength. In order to form the dispersed islands-in-the-sea composites, and the islands-in-the-sea composites reflect the shear wave (S wave) of a desired wavelength, the first component fed to the first component and the first component fed from the extruded portion to which the second component is fed. A spin block portion including an island-in-the-sea type extrusion mold including a portion distribution plate having a portion or all of the diameter or cross-sectional area of the island-based feed passages in which a component and a second component are added to form an island-in-the-sea composite flow, wherein A feed block part for laminating a skin layer on at least one surface of the island-in-the-sea composite compound conveyed from the spin block part by communicating with an extruder into which a keen layer component is injected, and a sea island type composite product having a skin layer conveyed from the feed block part laminated It includes a flow control unit for inducing the spread so that one component forms a plate-like shape based on the vertical section.

20 is a schematic diagram of an apparatus for manufacturing a reflective polarizer in which a polymer is dispersed according to a preferred embodiment of the present invention. Specifically, the first extrusion part 220 to which the first component is injected, the second extrusion part 221 to which the second component is injected, and the third extrusion part 222 to which the skin layer component is injected are included. The first extrusion part 220 communicates with the spin block part C including the island-in-the-sea extrusion mold 223 and supplies the first component in a molten state. The second extrusion part 221 also communicates with the spin block part C and supplies the second component in a molten state to the island-in-the-sea extrusion mold 223 included therein. The island-in-the-sea type extrusion mold 223 produces the island-in-the-sea composites in which the first component is dispersed in the second component. The islands-in-the-sea extrusion mold 223 may be one. The islands-in-the-sea extrusion mold 223 may be the island-in-the-sea extrusion mold shown in FIG. 4 or 9. In addition, the diameter or cross-sectional area of the island component supply passage and / or the sea component supply passage included in the island-in-the-sea extrusion mold may be different. The island-in-the-sea composites manufactured through the island-in-the-sea extrusion mold 223 form a core layer, and the core layer is transferred to the feed block unit 224 and then laminated with the skin layer component transferred from the third extrusion unit 222. do. Therefore, the third extrusion part 222 and the feed block portion 224 may be in communication with each other. In addition, in FIG. 20, the core layer and the skin layer are laminated in the feed block unit 224, but may be laminated in the spin block unit C and the feed block unit 224 may be omitted. Thereafter, the core layer in which the skin layer is laminated is transferred to the flow control unit 225, and the spread of the first component is induced to form a plate shape. Preferably, the flow control may be a T-die or a coat-hanger die.

21 is a schematic diagram of an apparatus for manufacturing a reflective polarizer in which a polymer is dispersed according to another exemplary embodiment of the present invention. 20, the first extrusion part 220 transfers the first component to the first pressurizing means 230. The first pressurizing means 230 discharges the first component to the island-in-the-sea extrusion mold 223. The second extrusion part 221 transfers the second component to the second pressing means 231. The second pressurizing means 231 discharges the second component to the island-in-the-sea extrusion mold 223. On the other hand, it is also possible that there are a plurality of first and second pressing means. The island-in-the-sea type extrusion product 223 produces a island-in-the-sea composite product in which the first component is dispersed inside the second component. The first pressing means 230, the second pressing means 231, and the island-in-the-sea extrusion mold 223 form the spin block portion C.

According to a preferred embodiment of the present invention, there is provided a liquid crystal display device including the reflective polarizer of the present invention. Specifically, FIG. 22 is an example of a liquid crystal display device employing a reflective polarizer of the present invention, in which a reflecting plate 280 is inserted into a frame 270, and a cold cathode fluorescent lamp 290 is disposed on an upper surface of the reflecting plate 280. Is located. An optical film 320 is disposed on the upper surface of the cold cathode fluorescent lamp 290. The optical film 320 includes a diffusion plate 321, a light diffusion film 322, a prism film 323, a reflection type polarizer 324 and the absorption polarizing film 325 are stacked in this order, but the order of lamination may be changed depending on the purpose, or a part of the constituent elements may be omitted or a plurality of them may be provided. For example, the diffusion plate 321, the light diffusion film 322, the prism film 323, and the like may be omitted from the overall configuration and may be changed in order or formed at different positions. Further, a phase difference film (not shown) or the like can also be inserted at an appropriate position in the liquid crystal display device. Meanwhile, the liquid crystal display panel 310 may be positioned on the upper surface of the optical film 320 by being inserted into the mold frame 300.

The light emitted from the cold cathode fluorescent lamp 290 reaches the diffuser plate 321 of the optical film 320. The light transmitted through the diffusion plate 321 passes through the light diffusion film 322 in order to advance the proceeding direction of the light perpendicularly to the optical film 320. The film having passed through the light diffusion film 322 reaches the reflection type polarizer 324 after passing through the prism film 323, thereby causing light modulation. Specifically, the P wave passes through the reflection type polarizer 324 without loss, but light modulation (reflection, scattering, refraction, etc.) occurs in the case of the S wave and is reflected again by the reflection plate 280, which is the back surface of the cold cathode fluorescent lamp 290 And the properties of the light are randomly changed into a P wave or an S wave, and then pass through the reflective polarizer 324 again. And then reaches the liquid crystal display panel 310 after passing through the absorption polarizing film 325. [ As a result, when the reflective polarizer of the present invention is inserted into a liquid crystal display device due to the above-described principle, remarkable improvement in luminance can be expected as compared with a general reflective polarizer. Meanwhile, the cold cathode fluorescent lamp 290 may be replaced with an LED.

In the present invention, the use of the reflective polarizer is described mainly with respect to the liquid crystal display, but the present invention is not limited thereto, and can be widely used in flat panel display technologies such as projection display, plasma display, field emission display and electroluminescence display.

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

≪ Example 1 >

The process was performed as shown in FIG. 21. Specifically, a mixture of PEN having a refractive index of 1.65 as a first component and dimethyl terephthalate and dimethyl-2,6-naphthalene dicarboxylate as a second component in a molar ratio of 6: 4 was mixed with ethylene glycol (EG) and 1 : 2, a refractive index of 1.64 and a refractive index obtained by polymerizing 90 wt% of polycarbonate and 10 wt% of polycyclohexylene dimethylene terephthalate (PCTG) as a skin layer component 1.58 were injected into the first extruding portion, the second extruding portion and the third extruding portion, respectively. The extrusion temperature of the first component and the second component was 295 캜, and Cap. The polymer flow was calibrated through adjustment and the skin layer was subjected to an extrusion process at a temperature level of 280 占 폚. The first component was transferred to the first pressurizing means (Kawasaki gear pump) and the second component was also transferred to the second pressurizing means (Kawasaki gear pump). The discharge amount of the first pressurizing means is 8.9 kg / h in order, respectively, and the discharge amount of the second pressurizing means is 8.9 kg / h. An island-in-the-sea composite product was prepared using an island-in-the-sea extrusion mold as shown in FIG. Specifically, the fourth mold distribution plate T4 among the island-in-the-sea extrusion molds forms four groups as shown in FIG. 8, and the number of island component layers in each group is 200. The diameter of the detention hole of the island component supply path of the group A 81 is 0.17 mm, the diameter of the detention hole of the island component supply path of the B group 82 is 0.44 mm, and the detention of the island component supply path of the C group 83 is The diameter of the hole is 0.38 mm, the diameter of the detention hole of the island component supply passage of the group D 84 is 0.23 mm, and the number of the island component supply passages included in one layer is 10000. The diameter of the discharge port of the sixth distribution plate is 15 mm x 15 mm.

In the feed block having a three-layer structure, a skin layer component flowed through the flow path from the third extrusion part to form a skin layer on the upper and lower surfaces of the island-in-the-sea composites (core layer polymer). 13, 14 for correcting the flow rate and pressure gradient of the core layer polymer such that the aspect ratio of the island-in-the-sea composite product is 1/117330 in group A, 1/64470 in group B, 1/76590 in group C, and 1/94380 in group D. Spread was induced in a 1,260mm wide coat hanger die.

The core layer polymer in which the skin layer was formed was induced in the coat hanger die of FIGS. 13 and 14 to correct the flow velocity and the pressure gradient. Specifically, the width of the die inlet is 200 mm, the thickness is 20 mm, the width of the die outlet is 960 mm, the thickness is 2.4 mm, and the flow rate is 1 m / min. Then, a smoothing process was performed on the cooling and casting rolls and stretched 6 times in the MD direction. As a result, the major axis length of the first component was not changed but the minor axis length was decreased. Thereafter, heat setting was performed through an IR heater at 180 ° C. for 2 minutes to prepare a reflective polarizer in which a polymer as shown in FIG. 16 was dispersed. The refractive index (nx: 1.88, ny: 1.64, nz: 1.64) of the first component of the produced reflective polarizer was 1.64 and the refractive index of the second component was 1.64. Core layer thickness is 59 micrometers, and skin layer thickness is 170.5 micrometers on upper and lower surfaces.

<Example 2>

The process was carried out as in Example 1. Specifically, four groups are formed as shown in FIG. 8, and the number of island component layers in each group is 150. The number of island component supply paths included in one layer is 5625. The intermediate conditions were 1260 mm wide coat-hanger in the same condition as in Example 1 so that the aspect ratio of the island-in-sea composites was 1/87998 in Group A, 1/48352 in Group B, 1/57443 in Group C and 1/70785 in Group D. A spreading process was performed on the die. Thereafter, a reflective polarizer in which the polymer as shown in FIG. 16 was dispersed was manufactured by the same process as in Example 1. The refractive index of the first component of the prepared reflective polarizer was (nx: 1.88, ny: 1.64, nz: 1.64) and the refractive index of the second component was 1.62.

<Example 3>

The process was carried out as in Example 1. Specifically, PEN having a refractive index of 1.65 as the first component and 70 wt% of polycarbonate and polycyclohexylene dimethylene terephthalate (PCTG) as the second component have a refractive index of 1.59. First extrusion was performed on a polycarbonate alloy having a refractive index of 1.58, in which 90% by weight of polycarbonate and 10% by weight of polycyclohexylene dimethylene terephthalate (PCTG) were polymerized as a polycarbonate alloy and skin layer component. It injected | thrown-in to the part, 2nd extrusion part, and 3rd extrusion part. The intermediate conditions were 1260 mm in width so that the aspect ratio of the island-in-the-sea composite product in the same state as in Example 1 would be 1/455 in Group A, 1/250 in Group B, 1/297 in Group C, and 1/366 in Group D.

Spreading was performed on the coat-hanger die. Thereafter, a reflective polarizer in which the polymer as shown in FIG. 16 was dispersed was manufactured by the same process as in Example 1. The refractive index of the first component of the prepared reflective polarizer was (nx: 1.88, ny: 1.64, nz: 1.64) and the refractive index of the second component was 1.575.

&Lt; Comparative Example 1 &

A reflective polarizer for 32-inch LCDs including 25000 birefringent fibers made of PEN, the first component having a diameter of 0.158 μm, was prepared inside the CO-PEN substrate, which is the second component.

Comparative Example 2

The process was carried out as in Example 3. Specifically, PEN having a refractive index of 1.65 as the first component and 70 wt% of polycarbonate and polycyclohexylene dimethylene terephthalate (PCTG) as the second component have a refractive index of 1.59. First extrusion was performed on a polycarbonate alloy having a refractive index of 1.58, in which 90% by weight of polycarbonate and 10% by weight of polycyclohexylene dimethylene terephthalate (PCTG) were polymerized as a polycarbonate alloy and skin layer component. It injected | thrown-in to the part, 2nd extrusion part, and 3rd extrusion part. The discharge amount of the first pressurizing means was 4.5 kg / h in the same condition as in Example 1 except that the number of layers of the detention holes included in the fourth detention distribution plate was 800, and the diameters of the detention holes were all 0.17 mm. 2 The discharge amount of the pressurizing means is 8.9 kg / h. The intermediate conditions were carried out in the coat-hanger die so that the aspect ratio of the island-in-the-sea composites was 1/142 in the same state as in Example 1. Thereafter, a reflective polarizer in which the polymer as shown in FIG. 15 was dispersed was manufactured by the same process as in Example 3. The refractive index of the first component of the prepared reflective polarizer was (nx: 1.88, ny: 1.64, nz: 1.64) and the refractive index of the second component was 1.59.

<Experimental Example>

The following physical properties of the reflective polarizers prepared through Examples 1 to 3 and Comparative Examples 1 to 2 were evaluated, and the results are shown in Table 1 below.

1. Transmittance

Transmission axis transmittance and reflection axis transmittance were measured by ASTM D1003 method using COH300A analyzer of NIPPON DENSHOKU, Japan.

2. Polarization degree

The degree of polarization was measured using an OTSKA RETS-100 analyzer.

3. Relative luminance

In order to measure the brightness of the produced reflective polarizer, the following procedure was performed. The panel was assembled on a 32 "direct-type backlight unit equipped with a diffuser plate and a reflective polarizer, and the brightness was measured at nine points using a BM-7 meter of Topcon Co., and the average value was shown.

The relative luminance shows the relative values of the luminance of the other Examples 2 to 3 and Comparative Examples 1 to 2 when the luminance of the reflective polarizer of Example 1 is 100 (reference).

Relative luminance (%) Polarization degree (λ = 550nm) Polarization degree (λ = 650nm) Polarization degree Transmission axis transmittance Reflective axis transmittance Polarization degree Transmission axis transmittance Reflective axis transmittance Example 1 100 85% 88% 7% 83% 89% 8% Example 2 96 80% 88% 10% 78% 89% 11% Example 3 92 66% 88% 18% 65% 89% 19% Comparative Example 1 80 43% 89% 35% 35% 90% 43% Comparative Example 2 86 56% 89% 25% 52% 90% 28%

As can be seen from Table 1, it can be confirmed that the reflective polarizers of Examples 1 to 3 of the present invention have significantly improved optical properties compared to the reflective polarizers of Comparative Examples 1 and 2.

Since the reflective polarizer of the present invention has excellent light modulation performance, it can be widely used in fields where optical modulation is required. Specifically, it can be widely used in flat panel display technologies such as a liquid crystal display device, a projection display, a plasma display, a field emission display, and an electroluminescence display which require high brightness such as a mobile display, an LCD and an LED.

Claims (28)

A method of manufacturing a reflective polarizer in which a polymer is dispersed, comprising a core layer having a plurality of first components dispersed therein and a skin layer formed on at least one surface of the core layer.
(1) supplying the first component, the second component, and the skin layer component to the extruding portions, respectively;
(2) forming an island-in-the-sea composite compound in which a plurality of first components are dispersed inside the second component, wherein the island-in-the-sea composite compound reflects an S wave of a desired wavelength and forms an optical thickness of the first components differently. To this end, the island-in-the-sea composites are prepared by injecting the first component and the second component transferred from the extruder into a single island-in-the-sea type extrusion mold including part or all of different diameter or cross-sectional areas of the island component feed passages. Forming;
(3) laminating at least one surface of the islands-in-sea composites with the skin layer component transferred from the extrusion unit; And
(4) inducing spreading in the flow control unit such that the first component of the island-in-the-sea composite compound in which the skin layer is laminated forms a plate shape having an aspect ratio of 1/200 or less, which is a ratio of the short axis length to the long axis length based on the vertical section; Method for producing a reflective polarizer is dispersed polymer comprising a. The method of claim 1,
The mold distribution plate is a method of manufacturing a reflective polarizer dispersed in the polymer, characterized in that the island component supply paths to form a plurality of layers, the same diameter or cross-sectional area of the island-shaped mold holes forming the same layer. 3. The method of claim 2,
A method for manufacturing a polymer-dispersed reflecting polarizer, characterized in that the diameter or cross-sectional area of the island-like confinement holes forming different layers is different. 3. The method of claim 2,
A method of manufacturing a reflective polarizer in which a polymer is dispersed, wherein a plurality of layers having the same diameter or cross-sectional area of the conductive component confined holes included therein are formed. 5. The method of claim 4,
And the plurality of layers form a group, wherein the plurality of groups are formed. The method of claim 5,
And the group is three or more. The method of claim 5,
And said group is four or more. The method of claim 5,
A method of manufacturing a reflective polarizer in which a polymer is dispersed, wherein the number of layers included in a single group is 100 or more. The method of claim 5,
A method of manufacturing a reflective polarizer in which a polymer is dispersed, wherein the number of layers included in a single group is 200 or more. The method of claim 1,
The aspect ratio of the plate-shaped is 1/1000 or less, characterized in that the polymer dispersed reflective polarizer manufacturing method. The method of claim 1,
A method of manufacturing a reflective polarizer in which a polymer is dispersed, characterized in that the aspect ratio of the plate-shaped is 1/5000 or less. The method of claim 1,
The aspect ratio of the said plate-shaped is 1/20000 or less, The manufacturing method of the reflective polarizer in which the polymer was disperse | distributed. The method of claim 1, wherein the step (1) and (2)
And discharging the first component transferred from the extruder to the island-in-the-sea extrusion mold through a first pressing means. The method of claim 1, wherein the step (1) and (2)
And discharging the second component transferred from the extruder to the island-in-the-sea extrusion mold through a second pressurizing means. The method of claim 1, wherein the flow control unit is a T-die or a coat-hanger die. The method of claim 1, wherein after step (4),
And stretching the reflective polarizer in which the polymer is dispersed. 17. The method of claim 16,
After the stretching step, the method of manufacturing a reflective polarizer dispersed in a polymer, characterized in that the aspect ratio of the plate-shaped to 1/1000 or less. 17. The method of claim 16,
After the stretching step, the aspect ratio of the plate-shaped reflective polarizer manufacturing method characterized in that the polymer is 1/10000 or less. An apparatus for manufacturing a reflective polarizer in which a polymer is dispersed, comprising a core layer having a plurality of first components dispersed therein and a skin layer formed on at least one surface of the core layer.
Three or more extrusion parts into which the first component, the second component, and the skin layer component are separately added;
In order to form an island-in-the-sea composite flow in which the first component is dispersed inside the second component, and the island-in-the-sea composite flow reflects the shear wave (S wave) of a desired wavelength, the extruded part and the second component into which the first component is injected. A single island-in-the-sea type extrusion mold including a mold distribution plate in which part or all of the diameters or cross-sectional areas of the island-based feed passages that feed the first component and the second component transferred from the injected extruder to form the island-in-the-sea composite flow is formed. A spin block portion comprising;
A feed block portion in communication with the extruded portion into which the skin layer component is injected and laminating the skin layer on at least one surface of the island-in-the-sea composite products transferred from the spin block portion; And
The first component of the island-in-the-sea composite compound in which the skin layer transferred from the feed block unit is laminated spreads to form a plate shape having an aspect ratio of 1/200 or less, which is the ratio of the short axis length to the long axis length based on the vertical cross section based on the vertical cross section. Apparatus for manufacturing a reflective polarizer dispersed in a polymer comprising a flow control unit for inducing a. 20. The method of claim 19,
The plate-shaped device is a manufacturing apparatus of the reflective polarizer dispersed polymer, characterized in that the aspect ratio of the ratio of the short axis length to the long axis length based on the vertical cross section less than 1/2000. 20. The method of claim 19,
The plate-shaped device is a manufacturing apparatus of the reflective polarizer dispersed polymer, characterized in that the aspect ratio of the ratio of the short axis length to the long axis length relative to the vertical section is 1/10000 or less. 20. The method of claim 19,
The mold distribution plate is characterized in that the island component supply paths form a plurality of layers, and the same diameter or cross-sectional area of the island-based detention holes forming the same layer is different, and the diameter or cross-sectional area of the island-based detention holes forming different layers is different. Apparatus for producing a reflective polarizer in which a polymer is dispersed. The method of claim 22,
And said plurality of layers form a group, wherein said group is formed in plurality. 24. The method of claim 23,
Apparatus for manufacturing a reflective polarizer with a polymer dispersed therein, characterized in that the number of layers included in a single group is 100 or more. 20. The apparatus of claim 19, wherein the spin block unit comprises first pressing means for discharging the first component transferred from the extruder to supply the island-in-the-sea extrusion mold. 20. The apparatus of claim 19, wherein the spin block unit includes second pressing means for discharging the second component transferred from the extruder to supply the island-in-the-sea extrusion mold. 20. The apparatus of claim 19, wherein the flow control unit is a T-die. 20. The apparatus of claim 19, wherein the flow control unit is a coat-hanger die.

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