KR20150010479A - Method for producing film patterned retarder - Google Patents

Abstract

The present invention relates to a method for manufacturing a crosstalk free film patterned retarder (FPR) using a laser transfer process. The method includes the steps of: forming the photo-alignment in a first direction by emitting light to a first alignment film formed on a substrate through a first polarizing plate; forming a black matrix on the first alignment film with the photo-alignment in the first direction through the laser transfer using a transfer mask with multiple open areas; and forming the photo-alignment in a second direction to form the left or right eye area by emitting light to the alignment film with the black matrix through the photo-alignment mask and the second polarizing plate.

Description

[0001] The present invention relates to a film patterned retarder,

The present invention relates to a method for producing a film pattern reliader.

The stereoscopic image display device implements a 3D image using a stereoscopic technique or an autostereoscopic technique.

The binocular parallax method uses parallax images of right and left eyes with large stereoscopic effect, and can be divided into a spectacular method and a non-spectacular method. The spectacle method realizes a stereoscopic image by using polarizing glasses or shutter glasses to display the right-and-left parallax images in a direct-view type display device or a projector by changing the polarization directions of the parallax images in a time-division manner. In the non-eyeglass system, optical components such as a parallax barrier and a lenticular lens for separating the optical axis of the left and right parallax images are installed in front of or behind the display screen to realize a stereoscopic image.

In a stereoscopic image display apparatus using a spectacle method, a polarized light separating element such as a patterned retarder should be attached to a display panel in a polarizing spectacle method. The patterned retarder makes the polarizations of the left eye image and the right eye image displayed on the display panel different. When a viewer views a stereoscopic image in a stereoscopic image display apparatus using a polarizing glasses system, the user views the polarization of the left eye image through the left eye filter of the polarizing glasses by wearing polarized glasses, and the polarization of the right eye image is viewed through the right eye filter of the polarizing glasses You can feel the stereoscopic effect because you see it. On the other hand, the shutter glasses system alternately displays the left eye image and the right eye image on the display panel without attaching a separate polarization separation element to the display panel, opens the left eye shutter of the shutter eyeglasses synchronously with the left eye image, Open the right-eye shutter of the shutter glasses as far as possible. When a viewer views a stereoscopic image in a stereoscopic image display apparatus using a shutter glasses system, the user views the left eye image through the left eye shutter of the shutter eyeglasses by wearing the shutter eyeglasses, and sees the polarization of the right eye image through the right eye shutter of the shutter eyeglasses You can feel the stereoscopic effect.

The stereoscopic image display apparatus of the shutter glasses system does not need to add a polarized light separation element to the display panel, so that the price increase factor of the display panel is small, but the price is high because expensive shutter glasses are required. In terms of 3D image quality, the stereoscopic image display apparatus using the shutter glasses is vulnerable to flicker and 3D crosstalk because the left eye image and the right eye image are time-divided at predetermined time intervals. On the other hand, the polarizing glasses type stereoscopic image display device adds a polarized light separating element such as a pattern derridder to the display panel, and the price of the display panel is slightly increased. However, since the polarizing glasses are used at low cost, Respectively. In terms of image quality, the polarizing glasses type stereoscopic image display apparatus displays the left eye image and the right eye image on the display panel at the same time and is separated in units of lines. Therefore, compared with the shutter glasses type stereoscopic image display apparatus, the level of flicker and 3D crosstalk low.

The patterned retarder is composed of a glass patterned retarder (GPR) on which a patterned retarder is formed on a glass substrate, a film patterned retarder having a patterned retarder formed on the film substrate, FPR). In recent years, a film-type pattern-type retarder that can reduce the thickness, weight, and price of a display panel compared with a glass pattern-type retarder is preferred.

However, since the film-type pattern reliader has to form different patterns for each fine region corresponding to the pixel region, the manufacturing process is difficult and the configuration of the manufacturing apparatus is difficult. In addition, forming a face-to-face film-type pattern-type retarder is an expensive manufacturing apparatus through a complicated process. Therefore, a device and a process for manufacturing a film-type pattern-type retarder having a simple structure and a simple structure are indispensably required.

On the other hand, when a film-type patterned retarder is manufactured using a mask having a plurality of open regions, it may be impossible or difficult to align the mask or the like.

1. Korean Patent Publication No. 10-2011-0038854

It is an object of the present invention to provide a crosstalk free film pattern deleter which can be easily aligned with a mask and simplify a process and improve productivity and process efficiency, (FPR). ≪ / RTI >

According to an aspect of the present invention, there is provided a method of manufacturing a liquid crystal display device, comprising: forming light alignment in a first direction by irradiating light onto an alignment layer formed on a substrate through a first polarizing plate; Forming a black matrix on an alignment layer in which a light is magnified in the first direction through laser transfer using a transfer mask having a plurality of open regions; And forming a light alignment pattern in a second direction that forms a right eye or a left eye area by irradiating light onto the alignment layer on which the black matrix is formed through a second polarizer and a light alignment mask. do.

The manufacturing method according to the present invention may further include forming a liquid crystal coating layer on the alignment layer having the optical alignment pattern in the second direction.

In the method of forming a black matrix according to the present invention, the laser may be scanned in a transverse direction across a plurality of open regions, wherein the scan speed of the laser may be 1 to 10 m / s.

In the step of forming the light directing pattern in the second direction among the manufacturing method according to the present invention, the position of the light directing mask can be finely adjusted based on the black matrix.

In the present invention, the opening area of the transfer mask may be 500 to 5,000.

In the present invention, the substrate may be conveyed through a roll-to-roll process comprising a plurality of rolls, wherein the conveying speed of the substrate may be 10 to 50 m / min.

In the present invention, the beam diameter of the laser may be 1 to 10 mm, and the light sources of the laser may be arranged at a plurality of intervals of 5 to 50 cm.

In the present invention, the widths of the left eye region and the right eye region may be independently 100 to 500 mu m, and the width of the black matrix may be 30 to 100 mu m.

The present invention also relates to a base film; And a transfer layer formed on the base film. The present invention also provides a donor film for manufacturing a film pattern delitters.

The donor film according to the present invention may further include a release layer formed between the base film and the transfer layer, and may further include an adhesive layer formed on the transfer layer.

In the present invention, the base film may be a film containing a polyalkylene terephthalate, and the thickness of the base film may be 25 to 250 탆.

In the present invention, the transfer layer may include carbon black and a binder, and the carbon black may be dispersed in a solution phase of a melt dispersion method or a mill base suspension. The content of the carbon black may be, 5 to 50% by weight.

In the present invention, the binder may be crosslinked by heat or light after laser transfer, and the glass transition temperature of the binder may be equal to or higher than room temperature. The binder may be at least one selected from the group consisting of hydroxyl group, carboxyl group, epoxy group, isocyanate group, urethane group, An acrylic resin containing at least one functional group selected, a cellulose resin, a urethane resin and an acrylic resin.

According to another aspect of the present invention, there is provided a method of manufacturing a film pattern reliader using the donor film, comprising: forming light alignment in a first direction by irradiating light onto an alignment layer formed on a substrate through a first polarizing plate; Forming a black matrix on the alignment layer in which the light is magnified in the first direction through laser transfer using the donor film and the transfer mask having a plurality of open regions; Forming a light alignment pattern in a second direction that forms a right eye or a left eye area by irradiating light onto the alignment layer on which the black matrix is formed through a second polarizing plate and a light alignment mask; And forming a liquid crystal coating layer on the alignment layer on which the light alignment pattern in the second direction is formed.

According to the present invention, the alignment of the mask and the like is easy, the process is simple, and the productivity and process efficiency can be improved.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a manufacturing process diagram of a film pattern delitander according to an embodiment of the present invention; FIG.
2 is a plan view showing a pattern of a mask for a laser transfer and a film pattern reliader according to an embodiment of the present invention.
3 to 5 are sectional views of a donor film usable in the present invention.

The present invention relates to a method of manufacturing a film patterned retarder (FPR) in which crosstalk is remarkably reduced, and more particularly, to a method of manufacturing a film pattern retarder (FPR) using a laser transfer process .

The film pattern reliader (FPR) may include a substrate, an alignment film having a light alignment pattern, and a liquid crystal coating layer sequentially from the bottom.

Examples of the substrate include polyester films such as polyethylene terephthalate, polyethylene isophthalate and polybutylene terephthalate; Cellulose-based films such as diacetylcellulose and triacetylcellulose; Polycarbonate film; Acrylic films such as polymethyl (meth) acrylate and polyethyl (meth) acrylate; Styrene-based films such as polystyrene acrylonitrile-styrene copolymer; Polyolefin-based films such as polyethylene, polypropylene, cyclo-based or norbornene-based polyolefin-based films, and ethylene propylene copolymers; Polyimide-based films; Polyethersulfone-based films; Or a sulfone-based film.

The composition for forming an alignment film includes a polymer resin to which orientation is imparted by light irradiation. The polymer resin may be at least one selected from the group consisting of polyamide, polyimide, polyvinyl alcohol, polyamic acid, and polycinnamate. For example, a polymer exhibiting photo-crosslinking properties including a monomer containing a cinnamate group that can be photo-oriented by a photo-dispersing agent may be used.

The liquid crystal coating layer can be formed by coating a coating liquid containing a liquid crystal compound.

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

FIG. 1 is a schematic view showing a manufacturing process of a film pattern drifter according to an embodiment of the present invention. First, light is applied to an alignment film formed on a substrate 10 through a first polarizing plate 30, Thereby forming a light alignment pattern in the first direction constituting the region 16.

As the light source for photo-alignment 20, ultraviolet rays or the like can be used. When the polarized light is irradiated through the first polarizing plate 30, a light alignment pattern in the first direction is formed in the alignment film. Here, the first direction may refer to a direction inclined at a predetermined angle, for example, 30 to 60 degrees with respect to the black matrix 14 described later. The light alignment pattern may be, for example, a stripe pattern in which each pattern is inclined at about 45 degrees and arranged at regular intervals in parallel. The light directing pattern in the first direction forms the left eye region 12 or the right eye region 16 of the film pattern drawer. Substantially the first direction pattern can be formed simultaneously in the second direction pattern formation process described later.

On the other hand, although not shown in the drawing, a photo-alignment mask can be used as needed in the process of forming the first direction pattern. When the mask is not used, for example, a method in which the light source 20 is regularly flashed to form an exposure pattern as the film 10 is transported may be used.

Next, a black matrix 14 is formed through laser transfer using a transfer mask 70 having a plurality of open regions 72 in the left and right inner boundary regions on the alignment film on which the optical alignment pattern in the first direction is formed.

Laser transfer is a type of thermal transfer, which is a process of transferring using a photo-thermal conversion material that absorbs laser light and converts it into heat.

More specifically, the transfer layer 54 of the donor film 50 is transferred to the left and right inner boundary regions of the alignment film by using the donor film 50, transfer mask 70 and laser light source 80 to form black matrix 14 ).

A black matrix (BM) 14 forms a boundary region between the left eye region 12 and the right eye region 16 formed in the FPR.

The donor film 50 can be transported by separate transport rolls 60 and 90. [

Referring to FIG. 2, a plurality of open areas 72 are formed in the transfer mask 70, the number of open areas being dependent on the pixel size and the size of the entire display screen, The number may be 500 to 5,000.

For example, when 1,000 open regions 72 are formed in the transfer mask 70, laser direct transfer may be impossible at the same time as FPR mass production. Specifically, 1,000 laser beam sources are used. And alignment may not be possible.

In the present invention, the above-described alignment problem and the like can be solved by scanning the laser in the transverse direction (the direction of the large arrow shown in the upper part of FIG. 2) across the plurality of open regions 72.

Specifically, the BM 14 is placed on the FPR film 10 in such a manner that a laser scan is scanned in the lateral direction using a shadow mask in which the left and right inner boundary regions are opened as a transfer mask 70. [ Can be transferred.

The laser light source 80 can reciprocate in the horizontal direction for laser scanning. When there are a plurality of laser light sources 80, each light source 80 can move at the same time.

The laser beam emitted from the laser light source 80 may preferably have a beam diameter of 1 to 10 mm. When a plurality of laser light sources 80 are arranged, the distance between each laser light source may preferably be 5 to 50 cm. The laser scan speed may preferably be 1 to 10 m / s in the transverse direction.

Next, the alignment film on which the black matrix 14 is formed is irradiated with light through the second polarizing plate 110 and the light alignment mask 120 to form light in the second direction constituting the right eye region 16 or the left eye region 12 Thereby forming an alignment pattern.

As the light source for photo-alignment 100, ultraviolet rays or the like can be used. The polarizing direction of the second polarizing plate 110 may be perpendicular to the polarizing direction of the first polarizing plate 30. For example, the polarizing direction of the second polarizing plate 110 may be perpendicular to the polarizing direction of the first polarizing plate 30. Here, the vertical may mean an angle between 80 and 100 in a broad sense.

When the polarized light is irradiated through the second polarizing plate 110, a light alignment pattern in the second direction is formed in the alignment film. Here, the second direction may be a direction different from the first direction, for example, a direction that is symmetrical to the first direction with respect to the black matrix 14. The second direction may also be a direction that is inclined at a constant angle, for example, 30 to 60 degrees, as in the first direction. The light directing pattern in the second direction may be, for example, a stripe pattern in which each pattern is inclined at about 45 degrees and arranged at regular intervals in parallel, like the first direction pattern. The light directing pattern in the second direction forms the right eye region 16 or the left eye region 12 of the film pattern reliader.

In the step of forming the light directing pattern in the second direction, the position of the light directing mask 120 can be finely adjusted and aligned based on the black matrix 14.

That is, the optical alignment mask 120 can be fine-tuned in the second photo-alignment process based on the transferred line of the BM 14. This is because the BM 14 is easy to align the mask 120 in the boundary region. Alignment is easy because alignment of the mask 120 is afforded by the thickness of the BM 14 formed.

Finally, a liquid crystal coating layer is formed on the alignment layer in which the alignment pattern of the second direction is formed, thereby completing the production of the film pattern delitrator.

The liquid crystal coating layer can be formed by coating a coating solution containing a conventional liquid crystal compound by a conventional method. As the liquid crystal, a rod-like liquid crystal or a discotic liquid crystal can be used.

The substrate 10 on which the alignment film is formed can be transported through a roll-to-roll process having a plurality of transport rolls 40, At this time, the conveying speed of the substrate 10 may be 10 to 50 m / min, preferably 10 to 30 m / min. If the feeding speed is too low, there is a problem that the productivity is deteriorated. If the feeding speed is too high, there is a problem in formation of an alignment pattern of the alignment film.

As described above, in the present invention, the BM pattern mask and the film coated with BM are placed on the FPR film, and the laser is scanned in the lateral direction, so that the BM is accurately transferred between the left and right pixels, A large area FPR can be manufactured.

FIG. 2 is a plan view showing a pattern of a laser transfer mask (upper drawing) and a film pattern reliader (lower drawing) according to an embodiment of the present invention. The transfer mask 70 includes a plurality of open areas 72, In the present invention, the alignment problem described above can be solved by scanning the laser in the transverse direction across a plurality of open regions 72.

2, the FPR film 10 can be alternately repeatedly arranged with the left eye region 12 and the right eye region 16 bounded by the BM 14. As shown in Fig.

The widths of the left eye region 12 and the right eye region 16 are related to the pixel size of the display and may be 100 to 500 mu m, preferably 150 to 450 mu m. The width of the BM 14 may be 30 to 100 mu m, preferably 40 to 90 mu m. If the width is too narrow, the left-eye image and the right-eye image are simultaneously recognized and the effect of improving the crosstalk phenomenon deteriorates. If the width is too wide, the display brightness becomes too low.

3 to 5 are cross-sectional views of a donor film 50 usable in the present invention. The donor film of FIG. 3 includes a base film 52 and a transfer layer 54 The donor film of Figure 4 further comprises a release layer 56 formed between the base film 52 and the transfer layer 54 and the donor film of Figure 5 comprises the transfer May further comprise an adhesive layer (58) formed on the layer (54).

The base film 52 may be a transparent film containing polyalkylene terephthalate such as PET or PBT excellent in heat resistance and laser transmittance. Here, transparent means that the light transmittance is 70% or more, preferably 80% or more, more preferably 90% or more, and most preferably 95% or more.

The thickness of the base film 52 may be 25 to 250 탆, preferably 30 to 240 탆. If the thickness is too thick or too thin, a roll to roll process may be difficult.

The transfer layer 54 may be a carbon black-containing layer (CB layer) including carbon black and a binder.

The carbon black is a main material for forming the BM 14, and is a material capable of laser-transferring through photo-thermal conversion at the same time. Such carbon black can be uniformly dispersed in the transfer layer 54 in a solution phase combination of a melt dispersion method or a mill base suspension.

The content of the carbon black may be 5 to 50% by weight, preferably 10 to 40% by weight based on the total weight of the transfer layer. If the content of carbon black is too small, the light-heat conversion efficiency may be deteriorated, while if too large, the adhesion and durability may be deteriorated.

The binder can introduce a crosslinking reaction by heat (elevated temperature) or light (UV) irradiation after laser thermal transfer, for high temperature stability.

The glass transition temperature (Tg) of the binder is advantageously greater than room temperature because of blocking and contamination in the film process.

As the component applicable as the binder, there is an acrylic polymer resin, and further crosslinking is possible by introducing a hydroxyl group, a carboxyl group, an epoxy group or the like.

Further, a cellulose resin can be used, and crosslinking of the hydroxyl group and / or isocyanate group possessed by the cellulose resin itself is possible.

A urethane resin can also be used.

Further, a UV curable resin can be used. A polyfunctional acrylate and a UV reactive monomer can be used, and the base film 52 can be crosslinked through UV irradiation after coating on the base film 52, It is also possible.

The release layer 56 is a material which is easily vaporized from the base film 52 or deteriorates the adhesion between the base film and the BM layer 14 and functions to easily separate the transfer layer 54, Based water-repellent coating solution can be used.

The adhesive layer 58 functions to easily bond the transfer layer 54 separated from the base film 52 to the base material 10 and to easily form the BM 14, .

10: substrate on which an alignment film is formed
12: Left eye area
14: Black Matrix
16: Right eye area
20, 100: light source
30, 110: Polarizer
40, 60, 90, 130: Roll
50: donor film
52: base film
54: transfer layer
56:
58: Adhesive layer
70: Pre-use mask
72: open area
80: Laser light source
120: mask for photo-alignment

Claims (23)

Irradiating light onto an alignment layer formed on a substrate through a first polarizing plate to form a light alignment in a first direction;
Forming a black matrix on an alignment layer in which a light is magnified in the first direction through laser transfer using a transfer mask having a plurality of open regions; And
And forming a light alignment pattern in a second direction that forms a right eye or a left eye area by irradiating light onto the alignment layer on which the black matrix is formed through a second polarizing plate and a light alignment mask.
The method according to claim 1,
Wherein the transfer mask has an open area of 500 to 5,000.
The method according to claim 1,
Wherein the step of forming the black matrix scans the laser in a transverse direction across a plurality of open regions.
The method according to claim 1,
Wherein the beam diameter of the laser is from 1 to 10 mm.
The method according to claim 1,
Wherein the plurality of light sources of the laser are arranged at intervals of 5 to 50 cm.
The method of claim 3,
Wherein the laser scanning speed is 1 to 10 m / s.
The method according to claim 1,
Wherein the step of forming the light alignment pattern in the second direction aligns and aligns the position of the light alignment mask with reference to the black matrix.
The method according to claim 1,
Wherein the substrate is transferred through a roll-to-roll process comprising a plurality of rolls.
9. The method of claim 8,
Wherein the transfer speed of the substrate is 10 to 50 m / min.
The method according to claim 1,
Wherein the widths of the left eye region and the right eye region are independently 100 to 500 mu m.
The method according to claim 1,
Wherein the width of the black matrix is 30 to 100 占 퐉.
The method according to claim 1,
And forming a liquid crystal coating layer on the alignment layer on which the alignment pattern of the second direction is formed.
A base film; And
And a transfer layer formed on the base film.
14. The method of claim 13,
And a release layer formed between the base film and the transfer layer.
14. The method of claim 13,
And further comprising an adhesive layer formed on the transfer layer.
14. The method of claim 13,
Wherein the base film is a film comprising a polyalkylene terephthalate.
14. The method of claim 13,
Wherein the base film has a thickness of 25 to 250 占 퐉.
14. The method of claim 13,
Wherein the transfer layer comprises carbon black and a binder. ≪ RTI ID = 0.0 > 11. < / RTI >
19. The method of claim 18,
Wherein the content of the carbon black is 5 to 50% by weight based on the total weight of the transfer layer.
19. The method of claim 18,
Wherein the binder is crosslinkable by heat or light after laser transfer.
19. The method of claim 18,
Wherein the binder has a glass transition temperature of room temperature or higher.
19. The method of claim 18,
Wherein the binder is at least one selected from the group consisting of an acrylic resin, a cellulose resin, a urethane resin and an acrylic resin containing at least one functional group selected from the group consisting of hydroxyl group, carboxyl group, epoxy group, isocyanate group, urethane group and acrylic group ≪ / RTI > wherein the donor film comprises at least one of the following.
Irradiating light onto an alignment layer formed on a substrate through a first polarizing plate to form a light alignment in a first direction;
Forming a black matrix on the alignment layer in which the light is magnified in the first direction through laser transfer using a donor film according to any one of claims 13 to 22 and a transfer mask having a plurality of open areas; And
And forming a light alignment pattern in a second direction that forms a right eye or a left eye area by irradiating light onto the alignment layer on which the black matrix is formed through a second polarizing plate and a light alignment mask.

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