KR20200114982A - Method and apparatus for fabricating pattern sheet - Google Patents

Abstract

Provided are a method for producing a pattern sheet, and a device for producing a pattern sheet. The method for producing a pattern sheet comprises the steps of: forming a first pattern layer including a first surface concave-convex part on the upper surface of a first substrate; and forming a second pattern layer on the first pattern layer through a continuous process, wherein the second pattern layer is formed such that the sum of the thicknesses of the first pattern layer and the second pattern layer is uniform. The second pattern layer comprises a second surface concave-convex part having a complementary shape engaged with the first surface concave-convex part. The first pattern layer comprises a first pattern region and a second pattern region in which the first surface concave-convex part and the second surface concave-convex part have cross-sectional structures different from those of the first pattern region. According to the present invention, a defect caused by the first pattern layer is not visible on a laminate-type pattern sheet.

Description

[Method and apparatus for fabricating pattern sheet]

The present invention relates to a method and apparatus for manufacturing a pattern sheet in which a plurality of pattern layers having a complementary shape are stacked.

The laminated patterned sheet is used in the deep-lay device. Due to the recent enlargement of the display, there is a lot of demand for a pattern sheet having a size of 55 inches or more, but in the case of a pattern sheet corresponding to 55 inches or more, a plurality of patterns having a width of 1300 mm or more and a minimum diameter of several micrometers are formed on the front side It may be necessary to manufacture a roll, and if the plurality of patterns are linear and the pattern roll is to be processed in a width direction rather than a circumferential direction of the pattern roll or a direction tilted at a large angle from the circumferential direction, the manufacturing time is reduced due to high difficulty. Since it is long, has a low yield, and is very expensive, manufacturing cost can be significantly increased when forming a laminated pattern sheet having a wide width of 1300 mm or more.

In addition, in order to form a pattern sheet, a pattern sheet semi-finished product having a first pattern layer formed on a first substrate by a pattern roll and a primary pattern resin is prepared, and then a second pattern is formed on the surface of the first pattern layer. After the resin is applied, a second pattern layer having a shape complementary to the first pattern layer is formed by covering the second substrate and physically pressing it. The first pattern layer and the second pattern layer are each separately processed. During manufacture, defects formed in the first pattern layer may be recognized by the stacked pattern sheet, or may be recognized as stains on the stacked pattern sheet due to non-uniform thickness of the first and/or second pattern layers. As an alternative to the pattern roll, a method of forming a pattern using a soft mold is known, but since the soft mold includes a joint connecting both ends, and the pattern to which the joint is transferred shows a thickness non-uniformity, the above-described unevenness may occur. When the plurality of pattern layers each have a high light transmittance of 90% or more, it is inevitably more sensitive to appearance defects.

The problem to be solved by the present invention relates to a method of manufacturing a pattern sheet in which defects due to the first pattern layer are not recognized in the laminated pattern sheet.

Another problem to be solved by the present invention relates to an apparatus for manufacturing a pattern sheet in which defects due to the first pattern layer are not recognized in the laminated pattern sheet.

The problems of the present invention are not limited to the problems mentioned above, and other problems that are not mentioned will be clearly understood by those skilled in the art from the following description.

The method of manufacturing a pattern sheet according to an embodiment for solving the above problem includes forming a first pattern layer including a first surface irregularities on an upper surface of a first substrate, and on the first pattern layer in a continuous process. A step of forming a second pattern layer, comprising forming the second pattern layer so that the sum of the thicknesses of the first pattern layer and the second pattern layer is uniform, wherein the second pattern layer comprises the first Includes a second surface irregularities having a complementary shape meshing with the surface irregularities, the first pattern layer has a first pattern region, and the first surface irregularities and the second surface irregularities are different from the first pattern area And a second pattern region having a structure.

The apparatus for manufacturing a pattern sheet according to an embodiment for solving the other problem is an apparatus for manufacturing a pattern sheet including a first pattern forming unit and a second pattern forming unit, and the first pattern forming unit is a soft mold and a first resin supply A unit and a first substrate providing unit, wherein the second pattern forming unit includes a lamination unit, a second resin supply unit, and a second substrate providing unit, wherein the first pattern forming unit and the second pattern forming unit are continuous processes. It is connected by

Details of other embodiments are included in the detailed description and drawings.

According to embodiments, it is possible to improve productivity and reduce manufacturing cost by manufacturing in a continuous process using a film mold having high productivity and low cost.

In addition, defects caused by the joints of the first pattern layer produced from the film mold can be prevented, the thickness of the laminated pattern can be made uniform when the laminated pattern sheet is produced, and the film mold is applied and a continuous process using the same is performed. So the manufacturing cost can be reduced. In particular, it is possible to improve the productivity of a large laminated pattern sheet with a width of 1300mm or more. Furthermore, it is possible to improve the thickness uniformity of the first and/or second pattern layer.

The effects according to the present invention are not limited by the contents exemplified above, and more various effects are included in the present specification.

1 is a cross-sectional view of a pattern sheet according to an exemplary embodiment.
2 to 4 are cross-sectional views of pattern sheets according to various embodiments.
5 is a cross-sectional view of a pattern sheet according to another embodiment.
6 is a cross-sectional view of a pattern sheet according to another embodiment.
7 is a cross-sectional view of a roll-shaped pattern sheet according to an exemplary embodiment.
8 is a perspective view of a soft mold according to an embodiment.
9 is a cross-sectional view taken along line IX-IX' of FIG. 8.
10 is a cross-sectional view showing a process of manufacturing a pattern sheet using the soft mold of FIG. 8.
11 is a perspective view of a soft mold according to another embodiment.
12 is a cross-sectional view taken along line XII-XII' of FIG. 11.
13 is a cross-sectional view of a roll-shaped pattern sheet formed by using the soft mold of FIG. 11.
14 is a perspective view of a soft mold according to another embodiment.
15 is a cross-sectional view taken along line XV-XV' of FIG. 14.
16 is a cross-sectional view taken along line XVI-XVI' of FIG. 14.
17 is a perspective view of a roll-shaped pattern sheet formed by using the soft mold of FIG. 14.
18 is a flowchart of a method of manufacturing a pattern sheet according to an exemplary embodiment.
19 is a schematic diagram showing an apparatus and process diagram for manufacturing a patterned sheet according to an exemplary embodiment.
20 is a schematic diagram showing an apparatus and process diagram for manufacturing a patterned sheet according to another embodiment.

Advantages and features of the present invention, and a method of achieving them will become apparent with reference to the embodiments described below in detail together with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below, but will be implemented in various forms different from each other, and only these embodiments make the disclosure of the present invention complete, and common knowledge in the art to which the present invention pertains. It is provided to completely inform the scope of the invention to those who have it, and the invention is only defined by the scope of the claims.

When an element or layer is referred to as “on” another element or layer, it includes all cases where another layer or other element is interposed directly on or in the middle of another element. On the other hand, when a device is referred to as "directly on", it indicates that no other device or layer is interposed therebetween. The same reference numerals refer to the same components throughout the specification. "And/or" includes each and every combination of one or more of the recited items.

Although the first, second, and the like are used to describe various components, it goes without saying that these components are not limited by these terms. These terms are only used to distinguish one component from another component. Therefore, it goes without saying that the first component mentioned below may be the second component within the technical idea of the present invention.

The terms used in the present specification are for describing exemplary embodiments and are not intended to limit the present invention. In this specification, the singular form also includes the plural form unless specifically stated in the phrase. As used in the specification, “comprises” and/or “comprising” do not exclude the presence or addition of one or more other elements other than the mentioned elements.

Unless otherwise defined, all terms (including technical and scientific terms) used in the present specification may be used as meanings that can be commonly understood by those of ordinary skill in the art to which the present invention belongs. In addition, terms defined in a commonly used dictionary are not interpreted ideally or excessively unless explicitly defined specifically.

Spatially relative terms "below", "beneath", "lower", "above", "upper", etc., as shown in the figure It can be used to easily describe the correlation between a component and other components. Spatially relative terms should be understood as terms including different directions of components during use or operation in addition to the directions shown in the drawings. For example, if a component shown in a drawing is turned over, a component described as "below" or "beneath" of another component will be placed "above" the other component. I can. Accordingly, the exemplary term “below” may include both directions below and above. Components may be oriented in other directions, and thus spatially relative terms may be interpreted according to the orientation.

Terms used in the present specification "~ sheet", "~ film", "~ layer" and the like may be used interchangeably with the same meaning. In addition, the functional optical sheet, which is the term of the present specification, may be used as a meaning including an optical film, an optical plate, an optical film package, and the like.

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

1 is a cross-sectional view of a pattern sheet according to an exemplary embodiment.

For convenience of explanation, the surface of the sheet, film, or layer that lies in the upper direction in the drawing is referred to as the upper surface, and the surface that lies in the lower direction is referred to as the lower surface. However, the terms such as the upper surface and the lower surface are only used to relatively distinguish one surface or the other surface of the structure, and depending on the application example or arrangement direction of the pattern sheet 10, the surface referred to as the upper surface faces downward or It can be oriented in a variety of directions, such as facing the side.

In the drawing, the first direction D1 and the second direction D2 are directions perpendicular to each other. The side of the pattern sheet 10 may be parallel to any one of the first direction D1 and the second direction D2, but is not limited thereto.

Referring to FIG. 1, the pattern sheet 10 may be used as an optical sheet of a display device. For example, the pattern sheet 10 may be used as an optical sheet of a backlight unit of a liquid crystal display. Specifically, the pattern sheet 10 may be used as a wavelength conversion sheet, a prism sheet, a diffusion sheet, and a protective sheet of the backlight unit. As another example, the pattern sheet 10 may be used as a liquid crystal display panel or an optical sheet disposed on an organic light emitting display panel. Specifically, the pattern sheet 10 may be used as a privacy sheet, a sheet for reducing color change to increase color reproduction at a viewing angle, a bright room contrast ratio improving sheet having excellent contrast ratio even in a bright place, and an electromagnetic wave shielding sheet.

The pattern sheet 10 may be a stacked pattern sheet in which a plurality of layers are stacked. The pattern sheet 10 includes a first substrate 100, a first pattern layer 310 disposed on an upper surface of the first substrate 100, and a second pattern layer 310 disposed on the first pattern layer 310 ( 320). The pattern sheet 10 may further include a second substrate 200 disposed on the second pattern layer 320. In one embodiment, the lower surface of the first substrate 100 and the upper surface of the second substrate 200, which are outer surfaces of the pattern sheet 10, are flat and may be exposed to the outside without disposing other layers. In another embodiment, a functional coating layer (not shown) may be disposed on the lower surface of the first substrate 100 and/or the upper surface of the second substrate 200. Examples of the functional coating layer may include a hard coating layer, an antireflection layer, and an antifouling layer, but are not limited thereto.

The first substrate 100 and the second substrate 200 face each other. Each of the first substrate 100 and the second substrate 200 may have a uniform thickness.

Each of the first substrate 100 and the second substrate 200 may include a transparent resin. For example, the first substrate 100 and the second substrate 200 are polyethylene terephthalate (PET), polycarbonate (PC), polyethylene (PE), polypropylene (PP), polysulfone (PSF), polymethyl It may be made of a material conventionally applied to an optical film such as methacrylate (PMMA), triacetylcellulose (TAC), cycloolefin polymer (COP), or cycloolefin copolymer (COC). The light transmittance of the first substrate 100 and the second substrate 200 may be 90% or more. The first substrate 100 and the second substrate 200 may be made of the same material, but are not limited thereto.

A first pattern layer 310 is disposed on the upper surface of the first substrate 100. The upper surface of the first pattern layer 310 may include first surface irregularities including concave portions and convex portions (or a first pattern portion, an upper dotted line inside '310' in the drawing). The first pattern layer 310 may further include a first base portion (or a first relief layer, under the dotted line inside '310' in the drawing) integrally connecting each convex portion.

A second pattern layer 320 is disposed on the first pattern layer 310. The lower surface of the second pattern layer 320 may directly contact the upper surface of the first pattern layer 310. The lower surface of the second pattern layer 320 may include second surface irregularities including convex portions and concave portions (or the second pattern portion, under the dotted line inside '320' in the drawing). The first surface irregularities of the first pattern layer 310 and the second surface irregularities of the second pattern layer 320 may have a complementary shape meshing with each other. That is, the convex portions of the first surface irregularities have substantially the same shape as the concave portions of the second surface irregularities and may be engaged. The concave portions of the first surface irregularities have substantially the same shape as the convex portions of the second surface irregularities and may be engaged. The specific shape of the first surface irregularities will be described later.

The upper surface of the second pattern layer 320 may be in contact with the lower surface of the second substrate 200. The upper surface of the second pattern layer 320 may be generally flat, but is not limited thereto.

In an embodiment, unlike the first pattern layer 310, the second pattern layer 320 may include a base portion. In this case, each of the patterns of the second pattern layer 320 may be divided or divided by the convex portions of the first surface irregularities of the first pattern layer 310. In addition, at least a part of the convex portions of the first surface irregularities of the first pattern layer 310 may contact the lower surface of the second substrate 200.

In another embodiment, the second pattern layer 320, like the first pattern layer 310, has a second base portion (or a second relaxation layer, '320' in the drawing) connecting each convex portion of the second pattern layer 320. It may further include an upper dotted line). The thickness of the second base portion may be the same as the thickness of the first base portion, may be smaller than that, or may be greater than that. When the thickness of the second base portion is smaller than the thickness of the first base portion, the maximum thickness of the second pattern layer 320 may also be smaller than the maximum thickness of the first pattern layer 310. On the other hand, as will be described later, when the first pattern layer 310 has only light modulation characteristics and the second pattern layer 320 further has adhesive characteristics as well as light modulation characteristics, the thickness of the second base portion is It may be larger than the thickness of the base portion, and in this case, the maximum thickness of the second pattern layer 320 may also be larger than the maximum thickness of the first pattern layer 310.

The combined thickness of the first pattern layer 310 and the second pattern layer 320 may be uniform. In some embodiments, the height t10 of the first pattern layer 310 may not be uniform. For example, the first pattern area PTR1 and the second pattern area PTR2 to be described later may have different heights. In addition, a height difference may also occur between convex portions belonging to the first pattern region PTR1. In this case, the second pattern layer 320 formed on the upper surface of the first pattern layer 310 may perform a planarization function. That is, in a region in which the thickness (or height) t10 of the convex portion of the first pattern layer 310 is large, the thickness (or height) t21 of the concave portion of the second pattern layer 320 is relatively small, and the first pattern In an area where the thickness t10 of the convex portion of the layer 310 is small, the thickness t21 of the concave portion of the second pattern layer 320 is relatively large, so that the first pattern layer 310 and the second pattern layer 320 are generally The combined thickness can be kept uniform. As the sum of the thicknesses of the first pattern layer 310 and the second pattern layer 320 is uniform, the distance between the upper surface of the first substrate 100 and the lower surface of the second substrate 200 opposite thereto may also become uniform. have. Likewise, the sum of the thickness t11 of the concave portion of the first pattern layer 310 and the thickness t20 of the convex portion of the second pattern layer 320 corresponding thereto is uniform, and the convex portion of the first pattern layer 310 is It may be equal to the sum of the thickness t10 and the thickness t21 of the concave portions of the second pattern layer 320 corresponding thereto.

In a state in which the pattern sheet 10 is unfolded in a flat plate shape, the first substrate 100 and the second substrate 200 may be disposed in parallel.

Each of the first pattern layer 310 and the second pattern layer 320 may include a transparent resin. The first pattern layer 310 and the second pattern layer 320 are photocurable resins such as epoxy acrylate resins, urethane acrylate resins, and silicone acrylate resins, acrylic resins, urethane resins, and polyester resins, respectively. It may be formed by including a thermosetting resin such as. Each of the resins constituting the first pattern layer 310 and the second pattern layer 320 may have a light transmittance of 95% or more.

The second pattern layer 320 may further have adhesive properties. When the pattern sheet 10 includes the second substrate 200 and the second pattern layer 320 has high adhesive properties, the quality of lamination of the pattern sheet 10 itself may be improved. In addition, when the second pattern layer 320 is laminated with the second substrate 200 or the pattern sheet 10 without the second substrate 200 is laminated with an additional adherend, a separate coupling member may be omitted. have. In this case, the adhesive force of the second pattern layer 320 may be 500g/25mm or more, and more preferably 1000g/25mm or more. For example, when the second pattern layer 320 is attached to an alkali-free glass (Non-Alkali Glass, Corning Eagle XG Glass 0.7t), the adhesive strength between the glass and the second pattern layer 320 becomes 1500g/25mm or more. , When using the pattern sheet 10 as a surface film, even if a separate bonding member is not used, a solid bonding force can be implemented.

The first pattern layer 310 and the second pattern layer 320 may have a refractive index of about 1.4 to 1.7, or about 1.5 to 1.6, but are not limited thereto. In one embodiment, the first pattern layer 310 and the second pattern layer 320 may have the same refractive index. In this case, since a substantial optical interface is not formed at the interface between the first pattern layer 310 and the second pattern layer 320, light passing through the interface may go straight without refracting. In another embodiment, the first pattern layer 310 and the second pattern layer 320 may have different refractive indices. For example, when the refractive index of the first pattern layer 310 and the second pattern layer 320 is 0.1 or more, the interface between the first pattern layer 310 and the second pattern layer 320 forms an optical interface. It can perform a light modulation function, such as refracting or reflecting a traveling direction of light.

In one embodiment, the first pattern layer 310 and the second pattern layer 320 may be formed of the same material. In another embodiment, the first pattern layer 310 and the second pattern layer 320 may be formed of different materials. In some embodiments, the first pattern layer 310 and the second pattern layer 320 may have different constituent components, but have substantially the same refractive index. Here, the fact that the refractive index is substantially the same may be used to include not only the case where the refractive index is completely the same, but also the case where the difference in the refractive index is 0.01 or less.

In some embodiments, the second pattern layer 320 may have a Young's Modulus value smaller than that of the first pattern layer 310. When the second pattern layer 320 has a relatively smaller Young's modulus value, it has a relatively excellent resilience, and the first pattern layer 310 or the second pattern layer 320 of the adjacent pattern sheet 10 Even when pressing occurs due to a fine step, deformation caused by it can be reduced.

In FIG. 1, a case where the first pattern layer 310 is formed directly on the upper surface of the first substrate 100 and the second pattern layer 320 is formed directly on the lower surface of the second substrate 200 is illustrated. A functional coating layer such as a release layer may be further disposed between the upper surface of the substrate 100 and the first pattern layer 310 and/or between the lower surface of the second substrate 200 and the second pattern layer 320. In this case, the adhesion of the release layer to the pattern layer 300 is less than the adhesion of the second pattern layer 320 described above, and may be, for example, 5g/25mm to 30g/25mm, but is not limited thereto.

In some embodiments, a functional coating layer having opposite functions is provided between the upper surface of the first substrate 100 and the first pattern layer 310 and/or between the lower surface of the second substrate 200 and the second pattern layer 320. Can be placed. For example, a primer layer is further provided on the top surface of the first substrate 100, that is, between the first substrate 100 and the first pattern layer 310, to increase adhesion to the first pattern layer 310. And, on the lower surface of the second substrate 200, that is, between the second substrate 200 and the second pattern layer 320, a release layer for lowering the adhesion to the second pattern layer 320 may be further provided. have. Conversely, a release layer may be disposed on the upper surface of the first substrate 100 and a primer layer may be disposed on the lower surface of the second substrate 200.

Hereinafter, the uneven shape of the first pattern layer 310 and the second pattern layer 320 will be described in detail with reference to FIGS. 1 to 4.

2 to 4 are cross-sectional views of pattern sheets according to various embodiments.

First, referring to FIG. 1, the first surface irregularities of the first pattern layer 310 may have a prism shape having an isosceles triangle in cross section. Here, the equilateral side of the isosceles triangle becomes the surface of the first pattern layer 310, and the bottom side becomes a virtual line connecting the valleys of the first pattern layer 310. The prism shape of the first pattern layer 310 extends in a first direction, and convex portions and concave portions may be alternately arranged along a second direction crossing the first direction. In this case, the convex portion of the first pattern layer 310 may be the peak of the prism, and the concave portion of the first pattern layer 310 may be the valley of the prism. In the cross-sectional view, an isosceles triangle having a convex shape of the first surface unevenness and an isosceles triangle having a concave shape of the first pattern layer 310 may have the same shape. In this case, the shape of the concave portion and the convex portion of the second surface irregularities of the second pattern layer 320 in the cross-sectional view may also have the same isosceles triangle.

As an example of the pattern layer 301 of the other pattern sheet 10_1, the first surface irregularities of the first pattern layer 311 may have a prism shape having an asymmetric triangle in cross section as shown in FIG. 2. The cross-sectional shape of the first surface irregularities of the first pattern layer 311 may be a right triangle having one side of the convex portion as a hypotenuse. The cross-sectional shape of the second surface irregularities of the second pattern layer 310 may also have the same right triangle.

As an example of the pattern layer 302 of another pattern sheet 10_2, the first surface irregularities of the first pattern layer 312 may have a trapezoidal shape, as shown in FIG. 3. The convex portion of the first surface irregularities may have a lower side (a virtual line connecting the valley) longer than an upper side, and may have an equilateral trapezoidal shape with the same slope of the hypotenuse (lateral side). The cross-sectional shape of the second surface irregularities of the second pattern layer 322 may also have a conformal trapezoidal shape.

As another example of the pattern layer 303 of the pattern sheet 10_3, the first surface irregularities of the first pattern layer 313 may have a rounded side surface, as illustrated in FIG. 4. The example of FIG. 4 corresponds to the case of a hypotenuse curve in the example of FIG. 3. 4 illustrates a case in which the hypotenuse of the first surface irregularities is convex, and the hypotenuse of the second surface irregularities of the second pattern layer 314 complementary thereto forms a concave curve, but on the contrary, the hypotenuse of the first surface irregularities is concave. And the hypotenuse of the second surface irregularities may be convex.

5 is a cross-sectional view of a pattern sheet according to another embodiment. The embodiment of FIG. 5 illustrates that at least one of the first pattern layer 314 and the second pattern layer 324 in the pattern layer 304 of the pattern sheet 10_4 may further include particles therein. . Specifically, the first pattern layer 314 and the second pattern layer 324 are examples of the particles, including wavelength conversion particles and scattering particles, and the pattern sheet 10_4 is applied as a wavelength conversion sheet. Unlike illustrated, the wavelength conversion particles WCP1 and WCP2 and the scattering particles SCP may be disposed on only one of the first pattern layer 314 and the second pattern layer 324.

Referring to FIG. 5, the first pattern layer 314 and the second pattern layer 324 may include wavelength conversion particles WCP1 and WCP2 therein. The wavelength conversion particles WCP1 and WCP2 are particles that convert the wavelength of incident light, and may be, for example, quantum dots (QD), fluorescent materials, or particles of phosphorescent materials. When a quantum dot, which is an example of the wavelength conversion particles WCP1 and WCP2, will be described in detail, the quantum dot is a material having a crystal structure of several nanometers, and is composed of several hundreds to thousands of atoms. Because quantum dots are very small, they exhibit a quantum confinement effect. The quantum confinement effect refers to a phenomenon in which the energy band gap of the object increases when the object becomes smaller than the nano size. Accordingly, when light having a wavelength higher than the band gap is incident on the quantum dot, the quantum dot absorbs the light and becomes excited, and falls to the ground state while emitting light of a specific wavelength. The emitted wavelength light has a value corresponding to the band gap. By controlling the size and composition of the quantum dots, it is possible to control the luminescence characteristics due to the quantum confinement effect.

The quantum dots that can be applied to the present embodiment are not particularly limited as long as they are commonly used, but for example, Group II-VI compounds, Group II-V compounds, Group III-VI compounds, Group III-V compounds, and IV-VI It may include at least one of a Group compound, a Group I-III-VI compound, a Group II-IV-VI compound, and a Group II-IV-V compound.

The quantum dots may include a core and a shell overcoating the core. The core is not limited thereto, for example, CdS, CdSe, CdTe, ZnS, ZnSe, ZnTe, GaN, GaP, GaAs, GaSb, AlN, AlP, AlAs, AlSb, InP, InAs, InSb, SiC, Ca, It may be at least one of Se, In, P, Fe, Pt, Ni, Co, Al, Ag, Au, Cu, FePt, Fe2O3, Fe3O4, Si, and Ge. The shell is not limited thereto, for example, ZnS, ZnSe, ZnTe, CdS, CdSe, CdTe, HgS, HgSe, HgTe, AlN, AlP, AlAs, AlSb, GaN, GaP, GaAs, GaSb, GaSe, InN, It may include at least one of InP, InAs, InSb, TlN, TlP, TlAs, TlSb, PbS, PbSe, and PbTe.

The wavelength converting particles WCP1 and WCP2 may include a plurality of wavelength converting particles that convert incident light into different wavelengths. For example, the wavelength converting particle may include a first wavelength converting particle (WCP1) that converts incident light of a specific wavelength to a first wavelength and emits it, and a second wavelength converting particle (WCP2) that converts and emits the second wavelength. have. In an exemplary embodiment, the incident light may be a blue wavelength light, the first wavelength may be a green wavelength, and the second wavelength may be a red wavelength. For example, the blue wavelength may be a wavelength having a peak at 420 to 470 nm, the green wavelength may be a wavelength having a peak at 520 nm to 570 nm, and the red wavelength may be a wavelength having a peak at 620 nm to 670 nm. However, the blue, green, and red wavelengths are not limited to the above example, and should be understood to include all wavelength ranges that can be recognized as blue, green, and red in the art.

In the exemplary embodiment, the blue light incident on the pattern layer 304 is partially incident on the first wavelength converting particle WCP1 while passing through the pattern layer 304, converted into a green wavelength, and emitted, and the other part is It is incident on the second wavelength conversion particle WCP2, is converted into a red wavelength, and is emitted, and some of the remainder may be emitted as it is without being incident on the first and second wavelength conversion particles WCP1 and WCP2. Accordingly, the light passing through the pattern layer 304 includes all of the blue wavelength light, the green wavelength light, and the red wavelength light. White light or outgoing light of different colors can be displayed by appropriately adjusting the ratio of the emitted light of different wavelengths. The light converted to the pattern layer 304 is concentrated within a specific wavelength in a narrow range, and has a sharp spectrum having a narrow half width. Accordingly, when color is implemented by filtering light of such a spectrum with a color filter, color reproducibility may be improved.

The ratio of the emitted light may be adjusted by the content ratio of the first wavelength conversion particles WCP1 and the second wavelength conversion particles WCP2. For example, when the content of the first wavelength converting particles WCP1 is relatively large, light of the first wavelength is more emitted, and when the content of the second wavelength converting particles WCP2 is relatively large, the light of the second wavelength is more A lot is released. In an exemplary embodiment, the content ratio of the first wavelength converting particle WCP1 related to the green wavelength and the second wavelength converting particle WCP2 related to the red wavelength may be 5:1 to 14:1, and further 8:1 To 12:1.

Unlike the above exemplary embodiment, incident light is ultraviolet light, and three types of wavelength conversion particles that convert it into blue, green, and red wavelengths respectively are inside the first pattern layer 314 and the second pattern layer 324. It can also be arranged to emit white light.

The first pattern layer 314 and the second pattern layer 324 may further include scattering particles (SCP) therein. Scattering particles (SCPs) are non-quantum point particles, and may be particles without a wavelength conversion function. The scattering particles (SCP) scatter the incident light so that more incident light can be incident on the wavelength conversion particle side. In addition, the scattering particles (SCP) may play a role of uniformly controlling the emission angle of light for each wavelength. Specifically, when some of the incident light is incident on the wavelength converting particles WCP1 and WCP2 and then the wavelength is converted and emitted, the emission direction has a random scattering characteristic. If there are no scattering particles (SCP) in the pattern layer 304, the green and red wavelengths emitted after the collision of the wavelength converting particles (WCP1, WCP2) have scattering emission characteristics, but without collision of the wavelength converting particles (WCP1, WCP2). Since the emitted blue wavelength does not have a scattered emission characteristic, the emission amount of the blue/green/red wavelength may be different according to the emission angle. Accordingly, by giving scattering emission characteristics to blue wavelengths emitted without colliding the scattering particles (SCP) with the wavelength conversion particles (WCP1, WCP2), it is possible to similarly control the emission angle of light for each wavelength.

In order to effectively exhibit wavelength conversion efficiency and scatter emission characteristics, the content of the scattering particles (SCP) is preferably greater than or equal to the content (total) of the first and second wavelength conversion particles (WCP1, WCP2). However, if the content of the scattering particles (SCP) is too large, the transmittance of the pattern layer 304 may be reduced. For example, when the content of the scattering particles (SCP) exceeds 6 times the content of the first and second wavelength conversion particles (WCP1, WCP2), it is inappropriate to apply to a backlight assembly due to a decrease in transmittance. From this point of view, the content of the scattering particles (SCP) is the content (total) of the first and second wavelength converting particles (WCP1, WCP2) or more (total) of the first and second wavelength converting particles (WCP1, WCP2) It may have a range of 6 times or less.

The scattering particles (SCP) may be larger in size than the wavelength conversion particles (WCP1, WCP2). For example, as the scattering particles (SCP), SiO2, TiO2, ZnO, etc. having a size of several tens of nm to tens of um may be used. SiO2 may have a size of 0.1um to 20um, and in one embodiment, may have a size of 1.5um to 3.5um. TiO2 may have a size of 0.05um to 5um, and in one embodiment, may have a size of 0.19um to 0.48um. In the case of ZnO, it may have a size of 0.1um to 2um.

6 is a cross-sectional view of a pattern sheet according to another embodiment. 6 illustrates a case in which the second pattern layer 325 of the pattern layer 305 of the pattern sheet 10_5 includes light absorbing particles LAP therein. The pattern sheet 10_5 having such a structure may be applied as a privacy sheet or a contrast ratio improving sheet.

Referring to FIG. 6, the first uneven surface of the first pattern layer 315 and the second uneven surface of the second pattern layer 325 each have an equilateral trapezoidal shape in cross section. The light absorbing particles LAP are disposed inside the second pattern layer 325. The light absorbing particles LAP are not disposed inside the first pattern layer 315. In this case, it may be preferable that the second pattern layer 325 does not have a second base portion. Unlike illustrated, the light absorbing particles LAP may be disposed inside the first pattern layer 315 and may not be disposed inside the second pattern layer 325.

7 is a cross-sectional view of a roll-shaped pattern sheet according to an exemplary embodiment.

Referring to FIG. 7, the pattern sheet 10R1 may be manufactured in a roll shape. When the pattern sheet 10R1 is applied to a display device, it may be cut from the roll-shaped pattern sheet 10R1 to have a predetermined shape. The cut pattern sheet may have a rectangular shape, but is not limited thereto.

In the roll-shaped pattern sheet 10R1, the longitudinal direction is a direction to be wound or unwound, and the width direction is a direction perpendicular to the longitudinal direction. Since the longitudinal direction corresponds to the running direction of the sheet when manufacturing the roll-shaped pattern sheet 10, it may also be referred to as a longitudinal direction or MD (Machine Direction) direction. The width direction is a direction crossing the MD direction, and may also be referred to as a transverse direction or a TD (Transverse Direction) direction. In an exemplary embodiment, a prism-shaped extension direction of the first pattern layer 310 and the second pattern layer 320 of the pattern sheet 10 is a TD direction of the roll-shaped pattern sheet 10. The width in the TD direction of the roll-shaped pattern sheet 10 may be 1300 mm or more, but is not limited thereto.

The roll-shaped pattern sheet 10 may include a first pattern area PTR1 and a second pattern area PTR2. The first pattern area PTR1 is a normal pattern area (or an effective pattern area) in which the first surface irregularities of the first pattern layer 310 and the surface irregularities of the second pattern layer 320 described through FIGS. 1 to 6 are normally formed. ) Can be. The second pattern region PTR2 is a region having a cross-sectional structure in which the first surface irregularities of the first pattern layer 310 and the second surface irregularities of the second pattern layer 320 are different, and may be a dummy pattern region. The second pattern area PTR2 of the roll-shaped pattern sheet 10 may not be applied to the display device. That is, when forming the pattern sheet 10 applied to the display device, the roll-shaped pattern sheet 10R1 may be cut to include only the first pattern area PTR1 except for the second pattern area PTR2. The shapes of the first pattern layer 310 and the second pattern layer 320 in the second pattern region PTR2 are different from the first pattern region PTR1, but the first and second substrates 100 and 200 have different shapes. The height (or the total thickness of the pattern layer 300 combined with the first pattern layer 310 and the second pattern layer 320) may be uniform in both the first pattern region PTR1 and the second pattern region PTR2. have.

The second pattern area PTR2 may be a result of forming the roll-shaped pattern sheet 10R1 using a soft mold including a joint. Hereinafter, the second pattern region PTR2 will be described in more detail through a description of a process of forming the first pattern layer 310 using a soft mold.

FIG. 8 is a perspective view of a soft mold according to an exemplary embodiment, and FIG. 9 is a cross-sectional view taken along line IX-IX′ of FIG. 8, and is a cross-sectional view of a joint portion of the soft mold. 10 is a cross-sectional view showing a process of manufacturing a pattern sheet using the soft mold of FIG. 8.

8 to 10, the first surface irregularities of the first pattern layer 310 may be formed using the soft mold 20. The soft mold 20 has a pattern complementary to a target pattern to be formed on its surface. The first pattern layer ('310' in FIG. 1) having the first surface irregularities is pressed so that the surface pattern of the soft mold 20 having a complementary shape of the first surface irregularities comes into contact with the first resin layer (Imptint ), it can be formed by curing the first resin layer. As another example, a first resin layer is formed by supplying a first resin to the surface pattern of the soft mold 20 having a complementary shape of the first surface irregularities, and then cured to form the first pattern layer 310 having the first surface irregularities. ) Can also be formed. The first resin may be supplied on the surface pattern of the soft mold 20 or may be supplied on the upper surface of the first substrate 100, and both the surface pattern of the soft mold 20 and the upper surface of the first substrate 100 It may be supplied simultaneously or sequentially. The soft mold 20 may be reproduced and manufactured from a cylindrical or plate-shaped metal mold that is a hard mold.

Unlike the hard mold, the soft mold 20 may itself be in a sheet shape. The soft mold 20 may include a mold substrate 21 and a mold pattern 22 disposed on the mold substrate 21. Both ends of the soft mold 20 in the longitudinal direction may be connected to each other to form a loop shape. The loop-shaped soft mold 20 may be rotated while being over the guide roll GR. That is, the specific position of the soft mold 20 may move in the longitudinal direction along the loop shape. The specific position of the soft mold 20 is moved while being supplied with the first resin layer on the surface while passing through the first resin supply unit RPD1, and then in the first lamination unit PRR1, DRR. 100), the first resin layer may be transferred to the first substrate 100 side.

On the other hand, the surface shape of the soft mold 20 has a uniform repeating pattern along the length direction, but the joint portion CNR formed to form a loop shape may have a different pattern. Specifically, the soft mold 20 may further include a first adhesive tape 23 disposed on the joint CNR. Both ends of the sheet-type soft mold 20 may be attached and connected through the first adhesive tape 23. The first adhesive tape 23 may be disposed on the upper surface of the mold pattern 22 of the soft mold 20. Since the first adhesive tape 23 is disposed on the mold pattern 22, the surface of the first adhesive tape 23 may protrude in the thickness direction from the peak of the mold pattern 22. Accordingly, the surface shape of the soft mold 20 may further protrude from the joint CNR in the thickness direction. During the imprinting process, the convex portion of the soft mold 20 is transferred to the concave portion of the first pattern layer 310 and the convex portion of the soft mold 20 is transferred to the convex portion of the first pattern layer 310. When imprinting is performed by using, the first pattern layer 310 pressed by the joint CNR may have a concave portion having a thinner thickness.

In some embodiments, the soft mold 20 may further include a second adhesive tape 24 disposed on the lower surface of the mold substrate 21. The second adhesive tape 24 may be omitted.

The first pattern layer 310 pressed by the joint portion CNR of the soft mold 20 corresponds to the second pattern area PTR2 of FIG. 7, and the first pattern layer 310 in the second pattern area PTR2 The thickness of 310 (the thickness of the recess) may be smaller than the thickness of the recess (valley) of the first pattern layer 310 in the first pattern area PTR1. The length (width in the length direction) of the second pattern area PTR2 is larger than the repeating pattern pitch of the first pattern area PTR1, for example, 100 times to 500 times the unit prism width (width in the MD direction). It can be a range. In the roll-shaped pattern sheet 10R1 of FIG. 7, the first pattern area PTR1 and the second pattern area PTR2 may be alternately disposed at a predetermined period along the length direction.

11 is a perspective view of a soft mold according to another embodiment, and FIG. 12 is a cross-sectional view taken along line XII-XII' of FIG. 11 and is a cross-sectional view of a joint. 13 is a cross-sectional view of a roll-shaped pattern sheet formed by using the soft mold of FIG. 11.

11 and 12, the soft mold 20_1 according to the present embodiment is different from the embodiment of FIG. 8 in that the joint portion CNR is formed by laser welding. Both ends of the mold substrate in the joint CNR may be fused through laser welding. The laser used for laser welding may include, but is not limited to, an Alexandrite laser, a diode laser, and an Nd:YAG laser. The mold pattern 22 for a predetermined section is completely removed from the upper surface of the mold substrate 21 in the joint CNR, or a residual layer of the mold pattern 22 smaller than the thickness of the peak of the mold pattern 22 as shown in the drawing May have been placed. The residual layer of the mold pattern 22 may be a residual layer remaining by laser welding the mold pattern 22 and the mold substrate 21. A second adhesive tape 24 may be disposed on the lower surface of the mold substrate 21 in the joint CNR. The second adhesive tape 24 may be removed after laser welding is completed.

In the joint CNR of the soft mold 20_1 of FIG. 12, unlike the joint CNR of the soft mold 20 of FIG. 9, the residual layer of the mold pattern 22 may be recessed from the surrounding mold pattern 22. have. In one embodiment, the thickness of the remaining layer of the mold pattern 22 of the soft mold 20_1 may be smaller than the thickness of the peak of the mold pattern 22 and may be greater than or equal to the thickness of the valley of the mold pattern 22, but is limited thereto. no.

Referring to FIG. 13, when manufacturing the roll-shaped pattern sheet 10R2 using the soft mold 20_1 of FIG. 11, the shape of the first pattern layer 310 of the first pattern area PTR1 is FIG. 7. It is the same as the embodiment of, but the shape of the first pattern layer 310 of the second pattern area PTR2 is different from the embodiment of FIG. 7, and the shape of the concave joint CNR is transferred to have a predetermined thickness. have. The thickness of the first pattern layer 310 of the second pattern area PTR2 may be greater than the thickness of the valleys of the first pattern layer 310 of the first pattern area PTR1 and less than or equal to the thickness of the peaks. As another example, the thickness of the first pattern layer 310 of the second pattern area PTR2 may be greater than the thickness of the peak of the first pattern area PTR1. The length (width in the length direction) of the second pattern area PTR2 is larger than the prism repeat pattern pitch of the first pattern area PTR1, for example, 5 to 50 times the unit prism width (width in the MD direction) It can be in the range of.

14 is a perspective view of a soft mold according to another embodiment. 15 is a cross-sectional view taken along line XV-XV' of FIG. 14. 16 is a cross-sectional view taken along line XVI-XVI' of FIG. 14. 17 is a cross-sectional view of a roll-shaped pattern sheet 10 formed by using the soft mold of FIG. 14.

This embodiment exemplifies a case where the prism-shaped extension direction of the first pattern layer 310 and the second pattern layer 320 of the pattern sheet 10R3 is the MD direction of the roll-shaped pattern sheet 10. Referring to FIG. 17, the roll-shaped pattern sheet 10R3 includes a first pattern area PTR1 and a second pattern area PTR2, and each prism pattern is formed along the length direction of the first pattern area PTR1. It may be extended and then disconnected to reach the second pattern area PTR2. The length (width in the length direction) of the second pattern area PTR2 is greater than the prism repeating pattern pitch of the first pattern area PTR1, for example, 5 to 50 times the unit prism width (width in the TD direction) It can be in the range of.

Referring to FIG. 14, both ends of the soft mold 20_2 are connected through a joint CNR. The prism shape of the soft mold 20_2 mold pattern 22 extends along the loop direction. 14 illustrates a case in which both ends of the soft mold 20_2 are attached and connected through the first adhesive tape 23 and the second adhesive tape 24. However, the present invention is not limited thereto, and may be fused by a laser as in the embodiment of FIG. 12.

Unlike illustrated, the prism-shaped extension directions of the first pattern layer 310 and the second pattern layer 320 of the pattern sheet 10R3 are inclined with respect to the MD and TD directions of the roll-shaped pattern sheet 10R3. You can lose. For example, the prism shape extension direction may have an angle of 1° to 30° or an angle of 60° to 89° based on the MD direction.

As described above, the roll-shaped pattern sheets 10R1, 10R2, and 10R3 use the soft molds 20, 20_1, and 20_2 as described above, and the first pattern layer 310 is formed on the upper surface of the first substrate 100. And then forming the second pattern layer 320 and the second substrate 200 on the upper surface of the first pattern layer 310. When the coating or pattern forming process is discontinuously performed in the manufacturing process of the sheets, the sheet on which the intermediate coating is finished may be transported or stored in a rolled state. For example, the intermediate structure in which the first pattern layer 310 is formed on the upper surface of the first substrate 100 using the soft molds 20, 20_1, 20_2 as described above is wound in a roll shape and transported and/ Or you can keep it. In this case, in the rolled sheet, the upper surface of the first pattern layer 310 and the lower surface of the first substrate 100 may face each other in the wound portion. During the winding process, the sheet may receive pressure in the thickness direction, and the portion corresponding to the second pattern area PTR2 is not only smaller in length (width in the length direction) than the first pattern area PTR1, but also has a pattern shape. Since they are different, the first pattern layer 310 of the second pattern area PTR2 may be overlapped by winding to affect the lower surface of the opposed first substrate 100, and thus, the first substrate 10 The upper surface of the first pattern layer 310 facing the lower surface of) may also be affected.

For example, when the first pattern layer 310 shown in FIG. 7 is formed and wound, the protruding portion of the second pattern area PTR2 presses the lower surface of the first substrate 100 opposite to 1 A pressing failure may be caused in the first pattern layer 310 facing the lower surface of the substrate 100. When the first pattern layer 310 shown in FIG. 13 is formed and wound, the lower surface of the first substrate 100 is pressed toward the recessed portion of the second pattern area PTR2, so that the first substrate 100 is wound. Defects in pressing may be caused in the first pattern layer 310 facing the lower surface. The second pattern area PTR2 is removed and not used when applied to the pattern sheet 10 of the display device, but may affect the first pattern area PTR1 having a normal pattern during the winding process. As a result, the first pattern area PTR2 The pattern area PTR1 may be bent or deformed, and a linear unevenness defect of the pattern sheet 10 may occur.

In order to minimize the influence of the joint portion CNR of the soft molds 20, 20_1, and 20_2, the second pattern layer 320 is formed in a continuous process without a process of forming and winding the first pattern layer 310 below. ) Is proposed.

18 is a flowchart of a method of manufacturing a pattern sheet according to an exemplary embodiment. As shown in FIG. 18, the method of manufacturing a pattern sheet includes a step of forming the first pattern layer 310 on the upper surface of the first substrate 100 (S1), and the first pattern layer ( 310) may include forming the second pattern layer 320 (S2).

19 is a schematic diagram showing an apparatus and process diagram for manufacturing a patterned sheet according to an exemplary embodiment.

Referring to FIG. 19, an apparatus 50 for manufacturing a pattern sheet according to an exemplary embodiment includes a first pattern layer forming part PTS1 and a second pattern layer forming part PTS2.

The first pattern layer forming part PTS1 may include a soft mold 20, a first resin supply unit RPD1, and a first curing device PCR1 and MCR1. The first pattern layer forming part PTS1 may further include a guide roll GR, first lamination parts PRR1 and DRR, and/or a first substrate providing part SPD1. The first substrate of the first substrate providing unit (SPD1) may be a finished product in which one or more pattern layers or functional layers are formed on the other surface of the first substrate, or may be another pattern sheet manufactured by the pattern sheet manufacturing apparatus 50. In this case, a configuration corresponding to the above-described first pattern layer, second pattern layer, and second substrate may be formed on the other surface of the first substrate.

The soft mold 20 may have a loop shape with the lower surface side of the mold base material 21 spanning the guide roll GR and the drum roll DRR.

The first resin supply unit RPD1 may be disposed on the traveling path of the soft mold 20. The first resin supply unit RPD1 supplies the first resin onto the mold pattern 22 of the soft mold 20. The first resin supply unit RPD1 may include at least one first water tank BTH1 and at least one first coating roll SMR1. The first coating roll SMR1 may have an elastic layer made of rubber or urethane material on its surface. The first water tank BTH1 may contain a first resin. The first resin may contain a photocurable material. In the case where the first pattern layer 310 includes particles therein, the first resin may also include the particles.

The first coating roll SMR1 may be disposed between the first water tank BTH1 and the soft mold 20. Specifically, the first water tank BTH1 is disposed below, the first coating roll SMR1 is disposed thereon, and the upper surface of the mold pattern 22 is first coated on the first coating roll SMR1. The soft mold 20 may be disposed to face the roll SMR1. The first coating roll SMR1 may be installed to be rotatable. The first coating roll SMR1 is disposed so as to contact the first resin of the first tank BTH1 and the mold pattern 22 of the soft mold 20, and transfers the first resin from the first tank BTH1 on the surface. It is supplied and rotates in the same direction as the transport direction of the soft mold 20 and may serve to transfer it to the upper surface of the mold pattern 22.

The first coating roll SMR1 may be plural. The plurality of first coating rolls SMR1 may be disposed adjacent to each other. The soft mold 20 may sequentially receive a first resin from each of the first coating rolls SMR1 while passing through the plurality of first coating rolls SMR1 in sequence. When the soft mold 20 receives a small amount of the first resin from several first coating rolls (SMR1), the generation of air bubbles is suppressed compared to receiving a large amount of first resin from one first coating roll (SMR1) at once. Can be.

The first substrate providing unit 100 includes a first substrate roll. The first substrate 100 unwound from the first substrate roll is transported along the guide roll GR to move to the first lamination portions PRR1 and DRR. The first lamination part may include a first pressing roll PRR1 and a drum roll DRR. The first substrate 100 is a soft mold that moves on the drum roll DRR while passing through the space between the drum roll DRR and the first pressing roll PRR1 disposed at a predetermined distance apart from the drum roll DRR at the top thereof. It approaches 20 and may contact the first resin disposed on the mold pattern 22 of the soft mold 20. The first resin in contact may be transferred from the soft mold 20 to the upper surface of the first substrate 100, and the first pattern layer 310 may be formed through a plurality of curing processes described later. In addition, the lowermost end of the first compression roll (PRR1) may be disposed similarly to each other to be positioned at a lower height than the uppermost end of the drum roll (DRR), although not shown in the drawing, the first compression roll (PRR1) and the drum Two dams (gaskets) and one or more suctions are provided between the rolls DRR at an interval narrower than the width of the soft mold 20, so that the first resin remaining when the first pattern layer 310 is formed is a soft mold. It is possible to prevent the occurrence of defects in the soft mold 20 or the first pattern layer 310 by leaking out to the side of (20). The thickness t10 of the first pattern layer 310 may be adjusted by the interval between the drum roll DRR and the first compression roll PRR1. Specifically, the thickness t11 of the first base portion may be adjusted according to the distance between the drum roll DRR and the first pressing roll PRR1. For smooth circulation of the soft mold 20, an elastic layer made of rubber or urethane may be provided on the surface of the drum roll DRR.

The first resin transferred from the soft mold 20 may be cured through the first curing devices PCR1 and MCR1. The first curing apparatus PCR1 and MCR1 may include a first temporary curing apparatus PCR1 and a first main curing apparatus MCR1. The first temporary curing device PCR1 may irradiate low pressure UV, and the first main curing device MCR1 may irradiate high pressure UV with a higher amount of light. The first temporary curing device PCR1 is disposed in the vicinity of the drum roll DRR, and the first resin can be temporarily cured at the same time as or immediately after the first resin is transferred to the upper surface of the first substrate 100. The first main curing device MCR1 completely cures the first resin temporarily cured by being disposed on the travel path of the first substrate 100 to form the first pattern layer 310. Accordingly, the first substrate 100 and the first pattern sheet on which the first pattern layer 310 is formed may be manufactured. The first pattern sheet completed by forming the first pattern layer 310 is transferred to the second pattern layer forming part PTS2 without being wound. The shape of the first pattern layer 310 of the first pattern sheet may be different from each other in the first pattern region PTR1 and the second pattern region PTR2 as described above. However, since it is not wound in the state of the first pattern sheet and is transferred directly to the step of forming the second pattern layer 320, it is possible that a pressing failure occurs due to the second pattern area PTR2 while the pattern sheet 10 overlaps. Can be prevented.

The second pattern layer forming part PTS2 may include a second resin supply unit RPD2 and second curing devices PCR2 and MCR2. The second pattern layer forming part PTS2 may further include a guide roll GR, lamination parts PRR2 and BKR, a blade BLD, and/or a second substrate providing part SPD2.

The second resin supply unit RPD2 may be disposed on the traveling path of the primary pattern sheet. The second resin supply unit RPD2 supplies a second resin on the upper surface of the first pattern layer 310 of the primary pattern sheet. The second resin supply unit RPD2 may include at least one second water tank BTH2 and at least one second coating roll SMR2. The second coating roll SMR2 may have an elastic layer made of rubber or urethane material on its surface. The second water tank BTH2 may contain a second resin. The second resin may contain a photocurable material. In the case where the second pattern layer 320 includes particles therein, the second resin may also include the particles.

When the second resin does not contain a solvent, the viscosity of the second resin may be 300 cps to 3000 cps. If the viscosity of the second resin is too low, such as less than 300 cps, bubbles may be generated inside during the coating process of the second resin, resulting in poor appearance, and high fluidity of the second resin may make it difficult to control the thickness. On the other hand, when the viscosity of the second resin exceeds 3000 cps, the second resin is not well filled into the valleys (concave portions) of the first pattern layer 310, and the production speed may be lowered. Therefore, the viscosity of the second resin is preferably 300 cps to 3000 cps, more preferably 500 cps to 1500 cps. When the second resin contains a solvent, it may have a viscosity of 300 cps or less or 300 cps or less.

The second coating roll SMR2 may be disposed between the second water tank BTH2 and the first pattern sheet. Specifically, a second water tank (BTH2) is disposed at the bottom, a second coating roll (SMR2) is disposed thereon, and the upper surface of the first pattern layer 310 is disposed on the second coating roll (SMR2). 2 The first pattern sheet may be disposed to face the coating roll SMR2. The second coating roll SMR2 may be installed to be rotatable. The second coating roll SMR2 is disposed so as to contact the upper surface of the second resin and the first pattern layer 310 of the second water tank BTH2, and receives the second resin from the second water tank BTH2 on the surface. It rotates in the same direction as the transfer direction of the first pattern sheet and may serve to transfer it to the upper surface of the first pattern layer 310.

The second coating roll SMR2 may be plural. The plurality of second coating rolls SMR2 may be disposed adjacent to each other. The first pattern sheet may sequentially receive a second resin from each of the second coating rolls SMR2 while passing through the plurality of second coating rolls SMR2 in sequence. When the first pattern sheet receives a small amount of second resin from several second coating rolls (SMR2), the generation of air bubbles will be suppressed compared to receiving a large amount of second resin from one second coating roll (SMR2) at once. I can.

The first pattern sheet supplied with the second resin is transferred to the second lamination units PRR2 and BKR, and a blade BLD is installed in the middle thereof to perform a squeezing process. The blade BLD may be installed to at least partially contact the surface of the second resin. When the primary pattern sheet supplied with the second resin is passed through the blade BLD, the surface thickness can be adjusted, and the uneven surface can be made uniform. In addition, when supplying the second resin to the first pattern sheet, the second resin may be partially unfilled on the valley of the first pattern layer 310, and such an unfilled space may be filled through a squeezing process. have.

The second substrate providing unit 200 includes a second substrate 200 roll. The second substrate 200 unwound from the second substrate 200 roll is transported along the guide roll GR. The second substrate 200 may be laminated while being in close proximity to the primary pattern sheet supplied with the second resin from the second lamination units PRR2 and BKR, and in contact with each other while passing through the second lamination units PRR2 and BKR. have.

The second lamination parts PRR2 and BKR may include a second pressing roll PRR2 (or gap roll) and a support roll BKR (or a back roll). The second pressing roll PRR2 and the support roll BKR may be disposed to face each other with a constant interval in the horizontal direction. The first pattern sheet and the second substrate 200 supplied with the second resin may proceed in a vertical direction or an up-down direction and may be laminated while passing between the second pressing roll PPR2 and the support roll BKR. The thickness of the pattern sheet 10 may be controlled by adjusting the distance between the second pressing roll PRR2 and the support roll BKR. The thickness t20 of the second pattern layer 320 may be adjusted by the gap between the second pressing roll PPR2 and the support roll BKR, and specifically, the thickness t21 of the second base may be adjusted. have. Although not shown in the drawing, two dams (gaskets) and one or more suctions are provided between the second pressing roll (PRR2) and the support roll (BKR) at a space narrower than the width of the first pattern sheet and the second substrate. By providing, it is possible to prevent the occurrence of defects due to leakage of the second resin remaining when forming the second pattern layer 320 to both sides.

The second resin may be cured through a second curing device (PCR2, MCR2). The second curing apparatus PCR2 and MCR2 may include a second temporary curing apparatus PCR2 and a second main curing apparatus MCR2. The second temporary curing device PCR2 may irradiate a low pressure UV, and the second main curing device MCR2 may irradiate a higher high pressure UV. In the case of the second temporary curing device (PCR2), it may be disposed on the side of the second substrate 200 provided from the second substrate providing unit SPD2, but the second substrate 200 includes a material that blocks or absorbs UV In this case, it may be disposed on the side of the primary pattern sheet, and the same can be applied to the embodiments described below. The second curing device (PCR2, MCR2) is disposed to be adjacent to or at the second lamination unit (PRR2, BKR), and the second resin is temporarily cured at the same time as or immediately after the second resin and the second substrate 200 are laminated. I can be upset. The second main curing device MCR2 may form the second pattern layer 320 by completely curing the second resin temporarily cured by being disposed on the travel path of the second substrate 200. The secondary pattern sheet on which the lamination and the second pattern layer 320 is formed may be wound in a roll shape as a completed pattern sheet 10R. Since the pattern sheet 10R to be wound has already formed the second pattern layer 320 on the second pattern area PTR2, the first pattern area PTR1 and the second pattern are viewed as a whole. The region PTR2 has a uniform thickness, and the lower surface of the first substrate 100 and the upper surface of the second substrate 200 may also have a flat surface without protrusions. Therefore, even if the pattern sheets 10R overlap by winding, a pressing failure or the like can be prevented. When the second pattern layer 320 is formed of a second resin having a predetermined modulus value after complete curing, it may be more advantageous in preventing a pressing failure. In this case, the thickness t21 of the second base portion formed on the second pattern layer 320 may be greater than the thickness t11 of the first base portion formed on the first pattern layer 310. In addition, the second pattern layer 320 may further have adhesive properties.

20 is a schematic diagram showing an apparatus and process diagram for manufacturing a patterned sheet according to another embodiment.

Referring to FIG. 20, in the apparatus 50_1 for manufacturing a pattern sheet according to the present embodiment, the arrangement of the configurations of the second lamination units PRR2 and BKR is different from the embodiment of FIG. 19. That is, the second lamination portion (PRR2, BKR) including the second pressing roll (PRR2) (or gap roll) and the support roll (BKR) (or back roll) is the same as the embodiment of Fig. 19, but the second pressing roll It is different from the embodiment of FIG. 19 in that the (PRR2) and the support roll (BKR) are arranged to face each other at regular intervals in the vertical direction (or vertical direction). In the present embodiment, the first pattern sheet and the second substrate 200 supplied with the second resin may be laminated while passing in a horizontal direction and passing between the second pressing roll PPR2 and the support roll BKR. In this embodiment as well, the thickness of the pattern sheet 10R can be controlled by adjusting the distance between the second pressing roll PRR2 and the support roll BKR.

Embodiments of the present invention have been described above with reference to the accompanying drawings, but those of ordinary skill in the art to which the present invention pertains can be implemented in other specific forms without changing the technical spirit or essential features of the present invention. You can understand. Therefore, it should be understood that the embodiments described above are illustrative in all respects and not limiting.

10: pattern sheet
100: first substrate
200: second base
300: pattern layer
310: first pattern layer
320: second pattern layer

Claims (15)

Forming a first pattern layer including first surface irregularities on an upper surface of the first substrate; And
Forming a second pattern layer on the first pattern layer in a continuous process, comprising forming the second pattern layer so that the sum of the thicknesses of the first pattern layer and the second pattern layer is uniform, ,
The second pattern layer includes a second surface irregularities having a complementary shape meshing with the first surface irregularities,
The first pattern layer is a method of manufacturing a pattern sheet including a first pattern region, and a second pattern region in which the first surface irregularities and the second surface irregularities have a different cross-sectional structure from the first pattern region. The method of claim 1,
The first pattern layer is formed by a soft mold including a joint,
The second pattern region is a method of manufacturing a pattern sheet formed by the joint. The method of claim 1,
The second pattern layer does not contain a solvent and is formed from a resin having a viscosity of 300 to 3000 cps. The method of claim 1,
The method of manufacturing a pattern sheet in which the first pattern layer and the second pattern layer have a refractive index difference of 0.1 or more. The method of claim 1,
The second pattern layer is a method of manufacturing a pattern sheet having a smaller Young's modulus value than the first pattern layer. The method of claim 1,
The second pattern layer is an adhesive layer having an adhesive strength of 1500 g/25 mm or more with glass. The method of claim 1,
The first pattern layer is a method of manufacturing a pattern sheet having a prism shape having a triangular or trapezoidal cross section. The method of claim 7,
At least one of the first pattern layer and the second pattern layer includes particles therein. The method of claim 8,
The particle is a method for producing a patterned sheet comprising wavelength conversion particles and scattering particles. The method of claim 8,
The particles include light absorbing particles,
The light absorbing particles are disposed inside the second pattern layer and are not disposed inside the first pattern layer. The method of claim 1,
The method of manufacturing a pattern sheet further comprising the step of disposing a second substrate on the second pattern layer. The method of claim 11,
After the step of disposing the second substrate, the method of manufacturing a pattern sheet further comprising the step of winding up the pattern sheet. A pattern sheet manufacturing apparatus comprising a first pattern forming portion and a second pattern forming portion,
The first pattern forming part includes a soft mold, a first resin supply unit, and a first base material providing part,
The second pattern forming unit includes a lamination unit, a second resin supply unit, and a second substrate providing unit,
The apparatus for manufacturing a pattern sheet in which the first pattern forming part and the second pattern forming part are connected in a continuous process. The method of claim 13,
An apparatus for manufacturing a patterned sheet in which no means for winding up the first substrate provided by the first substrate providing portion is present between the first pattern forming portion and the second pattern forming portion. The method of claim 13,
The apparatus for manufacturing a patterned sheet, wherein the lamination portion includes a second pressing roll and a support roll disposed to face the second pressing roll at regular intervals.

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