TWI444677B - Patterned retarder and manufacturing method of the same - Google Patents

Description

Patterned retardation sheet and method of manufacturing same

The present application claims the priority of the Korean Patent Application No. 10-2010-0075590 filed on Jan. 5, 2010, to the Korean Intellectual Property Office, the entire disclosure of which is hereby incorporated by reference.

The present invention relates to a patterned retardation sheet and a method of fabricating the same, and more particularly to a retardation sheet comprising a liquid crystal material pattern layer formed of a liquid crystal material contained therein, and a method of fabricating the same.

It is now expected to evolve from conversation-only services (such as the ones currently used) to high-speed information streaming services based on ultra-high-speed information communication networks, and become user-readable (including high-speed processing of text, sound and image digits). Terminal) multimedia service. It is expected that the service will be developed into an elastic three-dimensional information communication service that transcends space and can be seen, felt and enjoyed flexibly and three-dimensionally beyond the time and space.

The three-dimensional image usually presented in three dimensions is formed by the stereoscopic principle of both eyes. The main factor of the stereoscopic effect is the binocular aberration caused by the parallax of the two eyes which are usually spaced apart from each other by about 65 mm. Specifically, the left and right eye systems see different two-dimensional images, and the two images are transmitted to the brain via the retina. The brain then accurately combines the images to reproduce the depth and authenticity of the three-dimensional image, which is called stereoscopic imaging.

The above-mentioned technologies for expressing three-dimensional images are mainly classified into body technology and auto-stereoscopic technology. Among them, the stereoscopic technique uses a two-eye parallax image having a high stereoscopic effect, and includes a lens type method and a lensless type method. The lens type method using the principle of separating left and right eye images is classified into a space separation method (or a polarization method) and a time division method. The spatial separation method uses a patterned retardation film and the time separation method uses a shutter lens.

The spatial separation method (or polarization method) uses a polarizing phenomenon to attach the patterned retardation sheet to the entire surface of the display screen to stereoscopically separate the left and right eye images. A method of arranging a left eye image and a right eye image by patterning a delayed slice line is now widely used. For example, the left eye image is arranged on the singular line and the right eye image is arranged on the even line based on the vertical direction. In this case, the viewer wears polarized glasses and separately receives the left-eye image and the right-eye image separated by the display screen to view the 3-D image.

Fig. 1 shows a method of manufacturing a patterned retardation film according to the related art. As shown in FIG. 1, a method of manufacturing a patterned retardation film according to the related art includes applying a photocurable liquid crystal material 20 to a base member 10 (S10), irradiating the applied photocurable liquid crystal material with light and hardening the material. Forming the first liquid crystal material layer 30 (S20), coating the first liquid crystal material layer with the photocurable liquid crystal material 40 (S30), irradiating the photocurable liquid crystal material with the patterned mask, and unconfining the light The curable liquid crystal material is hardened (S40), and the second liquid crystal material layer 50 is formed by etching an uncured liquid crystal material having a predetermined pattern using an organic solvent (S50). In this case, the first liquid crystal material layer has a thickness which can retard the optical phase by λ/4, and the second liquid crystal material layer has a thickness which can retard the optical phase by λ/2. Thus, only the phase of the light passing through the first liquid crystal material layer is retarded by λ/4, and the phase of the light passing through the first liquid crystal material layer and the second liquid crystal material layer is retarded by 3λ/4.

However, according to the related art, since the method of manufacturing the patterned retardation film uses the photomask to form the pattern of the liquid crystal material, the mask alignment should be performed with high dimensional accuracy in order to accurately form the pattern. In this case, the adjustment time during the alignment process becomes long, and expensive equipment such as a photomask is required to be aligned with the exposure machine. Further, the method of manufacturing a patterned retardation film according to the related art requires separate etching procedures to control the phase lag difference, which results in a complicated procedure to obtain low yield and productivity.

The present invention has been made in an effort to provide a patterned retarder that minimizes the use of a mask and does not require the use of separate etching procedures.

Furthermore, the present invention has been made in an effort to provide a method of fabricating patterned retardation sheets that can produce a large number of patterned retarded sheets in a simple manner that does not require separate etching procedures.

An exemplary embodiment of the present invention provides a patterned retardation sheet comprising: a base member; a curable resin pattern layer formed of a curable resin coated on the base member, and having a pattern in which the first groove and the second groove are alternately arranged in a different depth; and a liquid crystal material pattern layer including a hard liquid crystal material which is accommodated in the first groove and the second groove of the curable resin pattern layer a first liquid crystal layer and a second liquid crystal layer. The first liquid crystal layer and the second liquid crystal layer retard the optical phase differently.

The base member can be a transparent member, and in particular a transparent glass member. The base member may be an elastic film, and in this case, the patterned retardation sheet may be manufactured by a Roll to Roll method.

The curable resin may be selected from a thermosetting resin or a photocurable resin, and is preferably an ultraviolet curable resin.

The photocurable resin may be a photocurable resin, and more preferably an ultraviolet curable resin.

The first liquid crystal layer may retard the optical phase (n-3/4) λ, and the second liquid crystal layer may retard the optical phase (n-1/4) λ, n may be a positive integer. In this case, one of the light components passing through the first liquid crystal layer and the second liquid crystal layer has a left circular polarization characteristic, and the other light component has a right circular polarization characteristic.

Another exemplary embodiment of the present invention provides a patterned retardation sheet comprising: a base member; a curable resin pattern layer formed of a curable resin coated on the base member, and having a pattern in which a plurality of grooves having a predetermined depth are arranged at predetermined intervals; and a liquid crystal material pattern layer including a first liquid crystal layer and a second liquid crystal having different thicknesses formed by a liquid crystal material coated on the curable resin pattern layer Floor. One portion of the first liquid crystal layer corresponds to the groove, and the second liquid crystal layer corresponds to a region on the groove interval, and the first liquid crystal layer and the second liquid crystal layer retard the optical phase differently.

Another exemplary embodiment of the present invention provides a method of manufacturing a patterned retardation sheet, comprising: coating a base member with a curable resin; using a first protrusion and a second protrusion formed on one surface thereof with different heights An imprinting master which is arranged in a staggered pattern, pressurizes and hardens the applied curable resin to form a curable resin pattern layer having a pattern in which first grooves and second grooves having different depths are alternately arranged; The curable liquid crystal material is filled and hardened into the first and second grooves of the curable resin pattern layer to form a liquid crystal material pattern layer including the first liquid crystal layer and the second liquid crystal layer. The first liquid crystal layer and the second liquid crystal layer retard the optical phase differently.

If the base member can transmit light emitted from the display screen, its material or shape is not limited to the designated one. The base member can be a transparent member, and in particular a transparent glass. The base member can be an elastic film. In this case, the patterned retardation sheet can be produced by a roll method.

The imprint master can be used in a general flat press method. The imprinting master mold is suitable for a roll method, and the imprint master may include a mother roll, a die roll, and a film forming die.

If the base member is a flexible film, the application of the curable resin and the formation of the curable resin pattern layer can be designed by the roll method, and the following specific examples can be given. A first exemplary embodiment of coating a curable resin and forming a curable resin pattern layer includes: (a1) conveying the base member to a surface formed thereon, wherein the first protrusion and the second protrusion having different heights are alternately arranged a patterned imprinting master roll; (a2) injecting a curable resin into a surface of the base member in close contact with a pattern formed on a surface of the imprinting master roll to fill the curable resin Between one surface of the base member and the pattern of the imprinting master roll; (a3) contacting one surface of the base member in close contact with the surface of the imprinting master roll on which the pattern is formed, and hardening the curable resin Forming a curable resin pattern layer having a pattern in which first grooves and second grooves having different depths are alternately arranged, and attaching the curable resin pattern layer to one surface of the base member; and (a4) The base member to which the curable resin pattern layer is attached is separated from the imprint master roll. In this case, the imprinting master roll has a pattern formed on the cylindrical metal surface in which the first protrusions and the second protrusions having different heights are alternately arranged.

A second exemplary embodiment of coating a curable resin and forming a curable resin pattern layer includes: (b1) conveying the base member to a surface formed thereon, wherein the first protrusion and the second protrusion having different heights are alternately arranged a patterned imprinting roller; (b2) injecting a curable resin into a region in which one surface of the base member is in close contact with a pattern formed on a surface of the imprinting stamper roll to apply the curable resin Filling a surface of the base member with the pattern of the imprinting stamper; (b3) contacting one surface of the base member in close contact with the surface of the imprinting stamper on which the pattern is formed, and hardening the curable resin Forming a curable resin pattern layer having a pattern in which first grooves and second grooves having different depths are alternately arranged, and attaching the curable resin pattern layer to one surface of the base member; and (b4) The base member to which the curable resin pattern layer is attached is separated from the imprinting stamper. In this case, the imprinting stamper roller has a stamper that is closely fixed to the surface of the cylindrical stay, and has a pattern in which the first projections and the second projections having different heights are alternately arranged.

A third exemplary embodiment of the present invention for coating a curable resin and forming a curable resin pattern layer includes: (c1) conveying a base member to a pattern roll using a guide roller; (c2) using a pattern guide roller to be on one surface thereof Forming a film-forming mold in which a pattern in which the first protrusions and the second protrusions of different heights are alternately arranged are conveyed to the pattern roll; (c3) injecting the curable resin into which one surface of the base member is closely attached a region of the pattern formed on one surface of the forming mold, wherein the curable resin is filled between one surface of the base member and the pattern of the forming mold; (c4) attaching one surface of the base member to the ground Forming the surface of the molding die on which the pattern is formed, and curing the curable resin to form a curable resin pattern layer having a pattern in which first grooves and second grooves having different depths are alternately arranged, and the hardenability is obtained The resin pattern layer is attached to one surface of the base member; and (c5) the base member to which the curable resin pattern layer is attached is separated from the molding die. In this case, the film forming mold includes: a film type base member layer; and a surface formed on one surface of the base member layer, and having a pattern in which first and second protrusions having different heights are alternately arranged Pattern layer. The film forming mold may further include: a rubbing unit formed on the other surface of the base member layer and having a frictional force against the surface of the roll. The base member layer of the forming mold may be formed of a PET film. Further, the pattern layer may be formed of a polymer resin. Further, the friction unit may be formed of a plurality of fine convex surfaces or a film formed of an elastic material.

Another exemplary embodiment of the present invention provides a method of manufacturing a patterned retardation sheet, comprising: coating a base member with a curable resin; forming a plurality of protrusions having a predetermined thickness formed thereon on a surface thereof at predetermined intervals a patterned master mold of the pattern, pressurizing and hardening the applied curable resin to form a curable resin pattern layer having a pattern in which a plurality of grooves having a predetermined depth are arranged at predetermined intervals; and the curable resin pattern The layer is coated with a curable liquid crystal material and hardened to form a liquid crystal material pattern layer including a first liquid crystal layer and a second liquid crystal layer having different thicknesses. The first liquid crystal layer corresponds to the groove, and the second liquid crystal layer corresponds to the interval between the grooves, and the first liquid crystal layer and the second liquid crystal layer retard the optical phase differently.

The patterned retardation film according to an exemplary embodiment of the present invention is compared to a patterned retardation film according to the related art having a structure in which the phase of the light is retarded differently using a pattern formed on one surface of the liquid crystal layer. The structure has a structure in which the phase of the light is retarded differently by using a liquid crystal material pattern layer formed of a liquid crystal material accommodated in the curable resin pattern layer. Therefore, the patterned retardation film can be manufactured by minimizing the etching process using the mask without separation. Further, the patterned retardation sheet according to the specific embodiment of the present invention can be manufactured by the roll method, which can be mass-produced using a simple method. In addition, if the patterned hysteresis film of the specific embodiment is attached to the front side of the display screen in accordance with the present invention, the user can provide a high quality 3-D image.

The above summary is illustrative only and is not intended to be limiting. In addition to the illustrative aspects, specific embodiments and features described above, other aspects, embodiments, and features are readily apparent.

Exemplary embodiments of the present invention are described in detail below with reference to the accompanying drawings. Reference numerals of the elements of the various figures should be noted first, and similar reference numerals indicate similar elements, even if similar elements appear in different drawings. In describing the present invention, the known functions or configurations are not described in detail to avoid unnecessarily obscuring the understanding of the present invention. It is to be understood that the specific embodiments of the present invention are described below, but the spirit of the present invention is not limited thereto, and those skilled in the art can change and modify the various aspects.

A patterned retardation film and a method of manufacturing a patterned retardation film according to an exemplary embodiment of the present invention are described with reference to FIGS. 1 through 12.

An illustrative embodiment of the invention is directed to a patterned retarder. 2 is a front elevational view of a patterned retarder in accordance with an exemplary embodiment of the present invention, and FIG. 3 is an exploded cross-sectional view of a patterned retarder in accordance with an exemplary embodiment of the present invention, and FIG. 4 is in accordance with the present invention. One is a combined cutaway view of a patterned retardation film of a specific embodiment.

As shown in FIGS. 2 to 4, a patterned retardation film according to an exemplary embodiment of the present invention includes a base member 110, a curable resin pattern layer 120, and a liquid crystal material pattern layer 130.

If the base member 110 can transmit light, its material or shape is not limited to the designated one. In order to smoothly transmit light, the base member may be a transparent member. Examples of the transparent member include a transparent glass member and a transparent plastic member. Further, the base member may be an elastic film. In this case, the patterned retardation sheet according to an exemplary embodiment of the present invention can be manufactured by the roll method.

The curable resin pattern layer 120 is formed of a curable resin coated on the base member. Further, the curable resin pattern layer has a series of patterns on the surface thereof in which the first grooves 121 and the second grooves 122 having different depths are alternately arranged. For example, when the depth of the first groove is 1 micrometer, the depth of the second groove is 3 micrometers. In this case, the thickness of the first liquid crystal layer described later is 1 μm, and the thickness of the second liquid crystal layer is 3 μm.

If the curable resin can transmit light, its material or shape is not limited to those specified. For example, a known curable resin such as a thermosetting resin or a photocurable resin can be used, and a photocurable resin is preferably used. The commercial purpose is more preferably a UV curable resin. On one surface of the curable resin pattern layer, a series of patterns in which the first grooves 121 and the second grooves 122 having different depths are alternately arranged are formed in a direction perpendicular to the horizontal direction or a horizontal direction of the base member. In this case, the pattern is formed by the imprinting method described later. In the patterned retardation sheet 100 according to the specific embodiment of the present invention, the thickness of the first liquid crystal layer and the second liquid crystal layer forming the liquid crystal material pattern layer described later is the first groove and the second groove of the curable resin pattern layer. The depth is controlled.

The liquid crystal material pattern layer 130 is formed of the first liquid crystal layer 131 and the second liquid crystal layer 132, which are alternately arranged with different thicknesses. Further, the first liquid crystal layer is formed of a curable liquid crystal material accommodated in the first groove of the curable resin pattern layer, and the second liquid crystal layer is cured by the second groove accommodated in the curable resin pattern layer. Formed by a liquid crystal material. The first liquid crystal layer and the second liquid crystal layer retard the optical phase differently. The curable liquid crystal material retards the optical phase differently depending on the predetermined thickness. If the curable liquid crystal material can change the polarizing characteristics of light, the material or shape thereof is not limited to those specified. For example, the curable liquid crystal material may be selected from the group consisting of a nematic phase, a disc phase, and a cholesterol phase (also referred to as a palm nematic phase). Further, the curable liquid crystal material may be a photocurable liquid crystal material. For commercial use, the curable liquid crystal material is more preferably a UV curable liquid crystal material. The photocurable liquid crystal material is a liquid crystal material which is cured by a photocrosslinking reaction when irradiated with light such as ultraviolet light. If the patterned retardation sheet 100 according to this exemplary embodiment is attached to the surface of a display screen such as an LCD, PDP, EL, or FED, a 3-D image display device can be formed. More specifically, when light emitted from the display screen is alternately arranged in a series of the first liquid crystal layer 131 and the second liquid crystal layer 132 with different thicknesses, the light is retarded by a different phase. Therefore, the light systems passing through the first liquid crystal layer 131 and the second liquid crystal layer 132 have different polarization characteristics. The viewer can use polarized glasses including two polarizing lenses corresponding to different polarizing features to recognize light of different characteristics with both eyes, and to sense 3-D images. In this case, the phase modulation characteristic of the light passing through the liquid crystal layer changes depending on the thickness of the liquid crystal layer and the optical anisotropy of the liquid crystal material, and Equation 1 below shows the relationship.

[Equation 1]

Optical phase hysteresis = n X t

Here, n means optical anisotropy of the liquid crystal material, and t represents the thickness of the liquid crystal layer.

The first liquid crystal layer forming the liquid crystal material pattern layer of the patterned retardation film 100 according to this embodiment may have a light phase retardation (n-3/4) λ (n is a positive integer), and the second liquid crystal layer may light Phase hysteresis (n-1/4) λ (n is a positive integer). In this case, one of the light components passing through the first liquid crystal layer and the second liquid crystal layer has a left circular polarization characteristic, and the other light component has a right circular polarization characteristic. The user can view high quality 3-D images using polarized glasses including a left eyeglass that selectively passes left circular polarization and a right eyeglass that selectively passes right circular polarized light. More specifically, if the optical anisotropy n of the liquid crystal material used is 0.17, in order to retard the optical phase with the first liquid crystal layer by λ/4 (λ is here the wavelength of light, for example, λ/4 is 137.5 mm) And the optical phase retardation of the second liquid crystal layer is 3λ/4 (λ is here the wavelength of light, for example, 3λ/4 is 412.5 mm), and the thickness of the first liquid crystal layer and the second liquid crystal layer should be 0.808 μm and 2.426, respectively. Micron. The thicknesses of the first liquid crystal layer and the second liquid crystal layer forming the liquid crystal material pattern layer of the patterned retardation sheet 100 according to this embodiment must be precisely controlled to the micron or nanometer level. Fine control of the thickness of the liquid crystal layer can be achieved by engraving with a curable resin pattern layer having a fine micron or nano pattern.

In the above description, the patterned retardation film according to the specific embodiment includes the first groove and the second groove formed on the curable resin layer coated on the base member, and the first formed thereon A liquid crystal layer and a second liquid crystal layer, but the invention is not limited thereto. Moreover, it may allow various examples without departing from the gist of the invention, such that a patterned retarder in accordance with an embodiment of the present invention may have first and second grooves formed on one surface of the base member, and at the substrate a first liquid crystal layer and a second liquid crystal layer formed in the first groove and the second groove of the member.

Another illustrative embodiment of the invention is directed to a method of making a patterned retardation sheet.

Figure 5 is a graph showing a method of fabricating a patterned retardation film in accordance with an exemplary embodiment of the present invention.

As shown in FIG. 5, a method of manufacturing a patterned retardation sheet according to the exemplary embodiment includes the steps of: coating a base member 100 with a curable resin (S100); and forming a surface having a height different in one surface thereof. An imprinting master 115 having a pattern in which the protrusions 116 and the second protrusions 117 are alternately arranged, and the applied curable resin is hardened and pressurized to form a first groove 121 and a second groove 122 in which the depths are different. a patterned curable resin pattern layer 120 (S200 and S300); and a hardenable liquid crystal material filled in the first and second grooves of the curable resin pattern layer and hardened to form a first liquid crystal layer and The liquid crystal material pattern layer 130 of the second liquid crystal layer (S400). In this case, the first liquid crystal layer and the second liquid crystal layer retard the optical phase differently. In addition, although not shown in FIG. 5, the method of fabricating the patterned retardation film according to the specific embodiment of the present invention may further include planarizing the liquid crystal material pattern layer using a CMP (Chemical Mechanical Polishing) device, and precisely controlling the first a step of thickness of a liquid crystal layer and a second liquid crystal layer. In the method of manufacturing a patterned retardation film according to an exemplary embodiment of the present invention, the liquid crystal material may be filled using a spin coating method, a roll coating method, a dispensing coating method, or a gravure coating method. In this case, the liquid crystal material can be diluted in a polymer solvent. The method of coating the liquid crystal material is usually determined depending on the type of solvent or the dilution ratio. Further, the liquid crystal layer is formed by irradiating the filled liquid crystal material with light such as ultraviolet light and performing a photocrosslinking reaction. Therefore, the optical phase modulation characteristic of the liquid crystal layer changes depending on the thickness of the liquid crystal layer and the optical anisotropy of the liquid crystal material. The thickness of the liquid crystal layer is not particularly limited, but is preferably several micrometers or less.

Meanwhile, the step of producing a curable resin and the step of forming a curable resin pattern layer in the method of patterning the retardation sheet according to the specific embodiment of the present invention are carried out by imprinting. It is possible to use a flat plate compression molding method which uses a flat plate imprinting master that conforms to the material or shape of the base member. It is also possible to use a continuous roll method which uses a roll type imprinting master. In the case where the continuous roll method is used, the manufacturing method and the improved productivity can be simplified to form a large-scale fine curable resin pattern layer. More specifically, if the base member is a flexible film, the patterned retardation sheet according to the specific embodiment of the present invention can be manufactured by the roll method. In this case, the imprinting master may include a master roll, a die roll or a film forming die, as described in detail below.

Fig. 6 is a graph showing a first exemplary embodiment of a step of coating a curable resin and a step of forming a curable resin pattern layer in a method of manufacturing a patterned retardation sheet according to an exemplary embodiment of the present invention. As shown in Fig. 6, the first exemplary embodiment of the step of applying the curable resin and the step of forming the curable resin pattern layer uses the imprint master roll 240 as an imprint master. The imprinting master roll is designed to form a pattern in which the first protrusions 241 and the second protrusions 242 having different heights are alternately arranged on the cylindrical metal surface, and is directly mounted on the manufacturing apparatus to be used.

The curable resin pattern layer forming apparatus using the imprinting master roll 240 as an imprinting master mold includes a first roll 220 and a second roll 250 that support and drive the base member 210 on both sides. The film-type base member 210 is wound around the first roller 220, and the base member 212 on which the curable resin pattern layer is formed is wound around the second roller 250. It provides a guide roller 230a to 230d for conveying the base member between the first roller and the second roller, and an imprint master roller 240 for forming a curable resin pattern layer on the base member. The portion in which the base member 210 is inserted into the imprinting master roll 240 has a curable resin injection tool 260 that provides a curable resin 262. Further, a hardening tool 270 that hardens the curable resin applied to the base member is provided in the vicinity of the imprinting master roll 240. When the base member 210 is unwound from the first roller 220, the base member 210 is conveyed along the guide rolls 230a to 230d to contact the imprinted master roll 240. In this case, the curable resin 262 is injected from the curable resin injection tool 260 to a portion where the base member is inserted into the imprinting master roll 240. One surface of the base member is closely attached to the surface of the imprinted master roll on which the pattern is formed, so that the base member 210 is coated with the pattern of the first groove and the second groove which are different in depth. Resin. The curable resin applied to the base member is hardened by heat or ultraviolet light emitted from the hardening tool 270 provided near the imprinting master roll 240. In this case, the guide roller 230b in which the base member 210 is embedded on the imprinting master roll 240 is used to control the gap of the curable resin pattern layer formed on the base member. That is, if the guide roller 230b is attached to the imprint master roll 240 in close proximity, the base member is thus attached to the imprint master roll 240 in close proximity. Therefore, the thickness of the curable resin pattern layer formed becomes small. Conversely, if the guide roller 230 is separated from the imprint master roll 240, the gap between the base member and the imprint master roll 240 becomes large. Therefore, a larger amount of the curable resin flows into the gap to cause an increase in the thickness of the curable resin pattern layer. The base member 212 on which the curable resin pattern layer having the pattern (the first grooves 213 and the second grooves 214 having different depths are alternately arranged) is formed to be guided by the guide roller 230c while being passed through the imprinting of the master roll 240 The master roll 240 is separated and then conveyed to wind the second roll 250.

In the method of manufacturing a patterned retardation sheet according to an exemplary embodiment of the present invention, the step of applying a curable resin and the second exemplary embodiment of the step of forming a curable resin pattern layer use an imprinting stamper instead of an imprinting master Roller.

Figure 7 is a plan view showing a second exemplary embodiment of a step of coating a curable resin and a step of forming a curable resin pattern layer in a method of fabricating a patterned retardation film according to an exemplary embodiment of the present invention. Cross-sectional view of the die roll. As shown in FIG. 7, it is provided with an imprinting stamper 340 to fix the stamper 341 having a pattern in which the first protrusions 342 and the second protrusions 343 having different heights are alternately arranged in the cylindrical support 344. a surface. The second exemplary embodiment of the step of applying the curable resin and the step of forming the curable resin pattern layer includes the steps of: (b1) conveying the base member to the first protrusion and the first portion thereof having different heights formed on the surface thereof a second impression stamping roller that protrudes in a staggered pattern; (b2) injecting a curable resin into a region in which one surface of the base member is in close contact with a pattern formed on a surface of the imprinting stamper roller, Filling the surface of the base member with the surface of the imprinting stamper with the curable resin; (b3) contacting one surface of the base member in close contact with the surface of the imprinting stamper on which the pattern is formed, and Curing the curable resin to form a curable resin pattern layer having a pattern in which first grooves and second grooves having different depths are alternately arranged, and attaching the curable resin pattern layer to one surface of the base member; And (b4) separating the base member to which the curable resin pattern layer is attached from the imprinting stamper roll.

In the step of coating the curable resin and the step of forming the curable resin pattern layer in the method of manufacturing the patterned retardation sheet according to the exemplary embodiment, the first exemplary embodiment using the imprinting master roll as the imprinting master is used. It has the advantage that the product quality is quite excellent. However, considering productivity, the pattern should be treated at least 500 mm or more, which causes a significant increase in the cost of processing the pattern. In addition, it is difficult to handle due to its weight and volume. In addition, there may be partial contamination due to work errors caused during the manufacture of the product, or manufacturing costs may increase due to the average life expectancy of scratch repair and wear. Meanwhile, the second embodiment using the imprinting stamper as the imprinting master is complicated in manufacturing the stamper, and the manufacturing stamper is time-consuming to increase in size of the stamper, making it difficult to manufacture a stamper having a uniform thickness, and during processing. There is some problem in that the stamp cannot be recovered when the stamp is folded or deformed. Usually, the stamper is used for small flat type compression molding. According to the continuous roll method, if the stamper is attached to the support, the joint 346a is formed at both ends. It may have an irregular pattern at the junction and may result in a substantial decrease in yield due to the short interval of irregular locations. In the process of producing a curable resin for patterning a retardation sheet and a process for forming a curable resin pattern layer, a problem may occur when an imprinting master roll or an imprinting stamper is used as an imprinting master, which can be used later in a A film-forming mold in which a pattern in which the first protrusions and the second protrusions having different heights are alternately arranged is formed on the surface as an imprinting master.

Fig. 8 is a graph showing a third exemplary embodiment of a step of coating a curable resin and a step of forming a curable resin pattern layer in the method of manufacturing a patterned retardation sheet according to an exemplary embodiment of the present invention. The third exemplary embodiment shows the use of a film forming mold as an imprinting master. The curable resin pattern layer forming apparatus uses a film forming mold 442 in which a pattern in which the first protrusions 443 and the second protrusions 444 are alternately arranged is formed on one surface as an imprinting master. The curable resin pattern layer forming apparatus includes a first roll 420 wound by the base member 410 on both sides, and a second roll 450 wound by the base member 412 on which the curable resin pattern layer is formed. Further, guide rollers 430a to 430e that transport the base member and the base member on which the curable resin pattern layer is formed are provided between the first roller 420 and the second roller 450. Further, the pattern molding unit 440 which forms the curable resin pattern layer on the base member 410 is disposed close to between the guide roller 430c and the guide roller 430d. The pattern molding unit 440 includes a film-forming mold 442 having a pattern, and the injected curable resin is pressed into a mold to form a curable resin pattern in accordance with the mold pattern, and the patterned curable resin is coated on the base member. The pattern roll 445 and the pattern guide rolls 446a and 446b for conveying the forming mold. The above-described forming mold 442 is formed by applying a pattern layer having a pattern onto a film-type base member layer, and has a long strip shape. Although FIG. 8 shows only a portion of the pattern formed on the pattern layer of the forming mold, in practice, a pattern is formed on all of the forming molds. The forming die 442 is formed such that the forming die covers the extension lines connecting the pattern roll 445 and the pattern guide rolls 446a and 446b, and connects the both ends of the forming die. In this case, since the joints formed by the two ends of the pattern mold 442 have a significantly longer interval than the joint surface of the stamper roll, the interval of the defective pattern generated at the joint surface is increased, which can be greatly improved. The yield of the base member 412 which forms a complete hardenable resin pattern layer. In order to increase the spacing of the joints, it is possible to form a longer forming die 442, and the distance between the pattern roll 445 and the pattern guide rolls 446a and 446b can be large. It provides a curable resin injection tool 460 of an injection-curable resin in a portion where the base member 410 is inserted into the pattern molding unit 440. Further, a hardening tool 470 that irradiates heat or ultraviolet light to harden the curable resin is provided in a portion where the base member and the molding die 442 move close to each other. However, in FIG. 8, the number of the guide rolls 430a to 430e and the pattern guide rolls 446a and 446b and their positions may be changed in accordance with the specific aspect. The base member 410 wound around the first roller 420 is first conveyed by the guide rolls 430a to 430c. In this case, the molding die 442 of the pattern molding unit 440 is moved and rotated by winding the pattern roller 445 and the pattern guide rollers 446a and 446b. In this case, since the pattern roller 445 is interlocked with the guide rollers 430c and 430d, the base member 410 is guided by the guide roller 430c to interlock with the forming die 442. Here, the guide roller 430c performs a gap control function to control the thickness of the curable resin pattern layer formed on the base member. More specifically, if the guide roller 430c is closely attached to the pattern roller 445, a thin curable resin pattern layer is formed. Conversely, if the guide roller 430c leaves the pattern roll, a thicker curable resin pattern layer is formed. In addition to the distance between the guide roller 430c and the pattern roller 445, the thickness of the curable resin pattern layer can be adjusted with respect to the viscosity of the curable resin, the patterning speed, and the tension of the base member. At the same time, in a portion where the guide roller 430c and the pattern roller 445 are interlocked, the curable resin is injected by the curable resin injection tool 460 to be pressed and filled between the pattern of the base member 410 and the molding die 442, and the guide roller 430c The pattern is uniformly dispersed by the pressure between the pattern roller 445. The curable resin dispersed between the base member 410 and the pattern of the forming mold 442 is hardened by heat or ultraviolet light emitted from the hardening tool 470. The base member on which the curable resin pattern layer is formed is taken out by the guide roller 430d to be separated from the molding die 442, and the base member 412 on which the entire curable resin pattern layer is formed is conveyed by the guide roller 430e to be wound up by the second Roller 450. The guide roller 430d performs a separating function here to separate the base member 412 on which the curable resin pattern layer is formed from the forming die 442. Further, although FIG. 8 shows only a part of the base member 412 on which the curable resin pattern layer is formed, the base member 412 on which the curable resin pattern layer is formed is actually wound around the second roll 450.

9 is a diagram showing another third exemplary embodiment of a step of coating a curable resin and a step of forming a curable resin pattern layer in a method of manufacturing a patterned retardation sheet according to an exemplary embodiment of the present invention. .

Another third exemplary embodiment shown in FIG. 9 is a modified embodiment of the pattern molding unit 410 shown in FIG. Specifically, a film-forming mold 542 in which a pattern in which the first protrusions 543 and the second protrusions 544 are alternately arranged is formed on one surface is formed into a long roll shape whose length corresponds to the length of the base member 510. Therefore, the base member 512 on which the complete curable resin pattern layer is formed does not have a joint. Referring to Fig. 9, a curable resin pattern layer forming apparatus for carrying out another third exemplary embodiment includes a first roll 520 wound by a base member 510 on both sides, and a curable resin pattern layer formed thereon. The base member 512 is wound by a second roller 550. Further, guide rollers 530a to 530f that transport the base member and the base member on which the curable resin pattern layer is formed are provided between the first roller 520 and the second roller 550. Further, the pattern roller 546 of the pattern molding unit 540 which forms the curable resin pattern layer on the base member 510 is disposed close to between the guide roller 530c and the guide roller 530d. The number and position of the guide rollers 530a to 530f can be modified here in accordance with the specific embodiment. The pattern molding unit 540 includes a film-forming mold 542 having a pattern, a third roller 545 wound by the mold, pressing the injected curable resin into a mold to form a curable resin pattern in accordance with the mold pattern, and The patterning curable resin is applied to the pattern roll 546 on the base member 510, the pattern guide rolls 547a to 547d of the forming mold, and the fourth roll 548 wound by the conveyed forming mold. The number and position of the pattern guide rollers 547a to 547d can be modified in accordance with the specific embodiment. The difference from the embodiment shown in FIG. 8 is that the forming die 542 is conveyed by the pattern roll 546 and the pattern guide rolls 547a to 547d to wind the third roll 545, and is formed of a curable resin on the base member 510. The pattern layer is then wound around the fourth roll 548. In this case, the forming mold 542 can be formed to have the same length as the base member 510. Thus, a pattern can be uniformly formed on all of the base members 512 on which the curable resin pattern layer is formed without a defective pattern or a discontinuous pattern due to the joint. Although FIG. 9 shows only a portion of the pattern formed on the pattern layer of the forming mold, in practice, a pattern is formed on all of the forming molds. It is provided with a curable resin injection tool 560 that injects a curable resin in a portion where the base member 510 is inserted into the pattern molding unit 540 (i.e., the guide roller 530c is closely attached to the pattern roller 546). Further, a hardening tool 570 that irradiates heat or ultraviolet light to harden the curable resin is provided in a portion where the base member and the molding die 542 move close to each other. First, the base member 510 wound around the first roller 520 is conveyed by the guide rollers 530a to 530c to be inserted into a portion where the guide roller 530c and the pattern roller 546 are interlocked. In this case, the forming mold 542 of the pattern molding unit 540 is also unwound from the third roller 545, and then conveyed between the insertion pattern roller 546 and the guide roller 530c by the pattern guide roller 547a to be closely attached to the base member 510. Here, the guide roller 530c performs a gap control function to control the thickness of the curable resin pattern layer formed on one surface of the base member. Meanwhile, since the curable resin is injected into the portion between the guide roller 530c and the pattern roller 546 (inserted into the base member 510) by the curable resin injection tool 560, the curable resin is applied to one surface of the base member and the molding die 542. The patterns are rolled and filled, and uniformly dispersed by the pressure between the guide rolls 530c and the pattern roll 546, and then hardened by heat or ultraviolet light emitted from the hardening tool 570. Therefore, the base member 5110 is coated with a patterned curable resin. The base member on which the curable resin pattern layer is formed is conveyed by the guide roller 530d and the guide roller 530e, and the molding die 542 is also conveyed by the guide roller 530d and the pattern guide roller 547b. Therefore, the base member and the molding die 542 on which the curable resin pattern layer is formed are attached between the guide roller 530d and the guide roller 530e, or are closely attached and transported between the guide roller 530d and the pattern guide roller 547b. Then, the base member 512 on which the curable resin pattern layer is formed is guided and conveyed by the guide roller 530f to wind the second roller 550. Further, the forming die 542 is guided and conveyed by the pattern guide rolls 547c and 547d to wind the fourth roll 548. The guide roller 530e and the pattern guide roller 547b each perform a separating function to separate the base member 512 on which the curable resin pattern layer is formed from the molding die 542. Meanwhile, as described above, if the length of the forming mold 542 is equal to the length of the base member 510, the curable resin pattern layer can be formed on all of the base members until the forming mold is unwound from the third roller 545, and then the fourth winding is again wound Roller 548. As a result, a defective pattern due to the joint was not generated on the base member on which the curable resin pattern layer was formed. Further, although FIG. 9 shows only a part of the base member 512 on which the curable resin pattern layer is formed, the base member 512 on which the curable resin pattern layer is formed is actually wound around the second roller 550.

Figure 10 is a view showing a third exemplary embodiment of a step of coating a curable resin and a step of forming a curable resin pattern layer in a method of manufacturing a patterned retardation sheet according to an exemplary embodiment of the present invention. Cross-sectional view of Fig. 11 is a cross-sectional view of another forming mold, and Fig. 12 is a cross-sectional view of still another forming mold. The film forming molds used in Figs. 8 and 9 are patterned on the curable resin injected by the curable resin injection tool, and are formed into a flexible film shape in which a pattern is formed on the polymer resin. Specifically, as shown in FIGS. 10 to 12, the forming molds 442, 642 or 742 have a two-layer structure including a base member layer 442a, 642a or 742a having a substantially uniform continuous flat surface, and a base member layer. A pattern layer 442b, 642b or 742b formed on one surface and having a pattern in which first and second protrusions having different heights are alternately arranged. Further, a forming die may be formed on the other surface of the base member layer, as shown in FIGS. 11 and 12, and may further include a friction unit 642c or 742c that increases friction against the surface of the roller. The material for the base member layer of the forming mold may be a film which is transparent, flexible, and has predetermined tensile strength and durability. Specifically, a PET film is preferred. Further, the resin material forming the pattern layer may be a mixture of a polymer material such as an oligomer or a curable primer. An example of a method of manufacturing a forming mold will be described below. First, a metal or film master is fixed, and then the master mold is coated with a molded polymer resin. Next, after the base member film for a molding die is overlaid on the master mold on which the polymer resin is applied, the cylindrical roller moves through the base member film to uniformly apply a predetermined pressure. In this case, the applied polymer resin is rolled and filled between the patterns of the master mold, and then uniformly dispersed by a predetermined thickness due to the pressure of the guide rolls. Next, the resin is filled in a contact state between the master mold and the base member film in accordance with the properties of the resin, the resin is hardened by irradiation of heat or ultraviolet light, and then the base member film is separated from the master mold. As for the base member film, if necessary, a base member film which is surface-trimmed to have adhesion to the molded polymer resin can be used. The forming mold can be produced by various methods other than the above manufacturing methods. At the same time, as shown in FIGS. 8 and 9, when the forming mold is mounted on the pattern roll and the pattern guide roll, the forming mold is closely fixed to the pattern roll and the pattern guide roll to form and form on the surface of the pattern roll or the pattern guide roll. It is important to have no air bubbles between the molds or to accumulate foreign matter. In this case, in order to improve the workability, the bubbles may be dissipated over time by forming small holes at regular intervals on the surface of the pattern roll or the pattern guide roll. Further, when the curable resin pattern layer forming device is driven, in order to reduce the bad pattern of the base member in which the entire hard curable resin pattern layer is formed and to improve the quality thereof, it is necessary to prevent the surface of the pattern roll or pattern guide roll from being formed between the forming mold Sliding. Therefore, as shown in Figs. 11 and 12, it is preferable to form a friction unit on the other surface of the base member layer of the forming mold. The forming die 642 shown in Fig. 11 includes a plurality of micron-thick convex faces 642c formed on the bottom of the base member layer 642a. Thus, the high frictional force between the surface of the pattern roll or pattern guide roll and the convex surface of the forming mold prevents the forming mold from slipping. In this case, the convex surface 642c may be made of an elastic material such as rubber or polyfluorene. Further, the forming mold 742 shown in Fig. 12 includes a film 742c formed on the bottom of the base member layer 742a to increase the friction against the surface of the pattern roll or the pattern guide roll. In this case, the film 742c is also made of an elastic material such as rubber or polyfluorene. Meanwhile, in addition to the above examples, various modifications/embodiments to prevent the sliding of the forming mold may be possible.

In the above description of the method of manufacturing the patterned retardation sheet according to the exemplary embodiment, the curable resin applied to the base member is formed on one surface in which the first protrusion and the second protrusion having different heights are alternately staggered The engraved master of the arranged pattern is pressed and hardened to form a curable resin pattern layer having a pattern in which the first grooves and the second grooves having different depths are alternately arranged, but the present invention is not limited thereto. The method of manufacturing a patterned retardation sheet according to the exemplary embodiment may include the step of forming a pattern in which a first protrusion and a second protrusion having different heights are alternately arranged on one surface after heat is applied to the base member. a mold pressurizing the base member, and forming a pattern in which the first groove and the second groove having different depths are alternately arranged on the base member, or forming a first protrusion on a surface in which the height is different After the heat is applied to the mold of the second protruding staggered pattern, the base member is pressurized with the mold, and a pattern in which the first grooves and the second grooves having different depths are alternately arranged is formed on the base member. Therefore, the exemplary embodiments can be modified in various ways without departing from the gist of the invention.

A patterned retardation film and a method of fabricating a patterned retardation film according to another exemplary embodiment of the present invention are described below with reference to FIGS. 13 through 23.

First, a patterned retardation film according to another exemplary embodiment of the present invention will be described.

13 is a front elevational view of a patterned retarder in accordance with another exemplary embodiment of the present invention, and FIG. 14 is an exploded cross-sectional view of a patterned retarder in accordance with an exemplary embodiment of the present invention, and FIG. A combined cross-sectional view of a patterned retardation film of a specific embodiment of the present invention.

As shown in FIGS. 13 to 15, a patterned retardation sheet 800 according to an exemplary embodiment of the present invention includes a base member 810, a curable resin pattern layer 820, and a liquid crystal material pattern layer 830.

If the base member 810 can transmit light, its material or shape is not limited to the one specified. In order to smoothly transmit light, the base member may be a transparent member. Examples of the transparent member include a transparent glass member and a transparent plastic member. Further, the base member may be an elastic film. In this case, the patterned retardation sheet according to an exemplary embodiment of the present invention can be manufactured by the roll method.

The curable resin pattern layer 820 is formed of a curable resin coated on the base member. Further, the curable resin pattern layer 820 has a series of patterns on its surface in which a plurality of grooves 822 having a predetermined depth are arranged at predetermined intervals. If the curable resin can transmit light, its material or shape is not limited to those specified. For example, a known curable resin such as a thermosetting resin or a photocurable resin can be used, and a photocurable resin is preferably used. The commercial purpose is more preferably a UV curable resin. On one surface of the curable resin pattern layer 820, a series of patterns in which a plurality of grooves 822 having a predetermined depth are arranged at predetermined intervals are formed in a vertical direction or a horizontal direction with respect to the base member. In this case, the pattern is formed by the engraving method described later.

The liquid crystal material pattern layer 830 is formed of a series of first liquid crystal layers 832 and second liquid crystal layers 831 which are alternately arranged with different thicknesses. Further, the first liquid crystal layer 832 is formed of a curable liquid crystal material applied in the inner region and the inner region of the groove 822 of the curable resin pattern layer 820, and the second liquid crystal layer 831 is coated with a curable resin pattern. The curable liquid crystal material on the gap region of the groove 822 of the layer 820 is formed. The first liquid crystal layer 832 and the second liquid crystal layer 831 retard the optical phase differently. The curable liquid crystal material retards the optical phase differently depending on the predetermined thickness. If the curable liquid crystal material can change the polarizing characteristics of light, the material or shape thereof is not limited to those specified. For example, the curable liquid crystal material may be selected from the group consisting of a nematic phase, a disc phase, and a cholesterol phase (also referred to as a palm nematic phase). Further, the curable liquid crystal material may be a photocurable liquid crystal material. For commercial use, the curable liquid crystal material may be a UV curable liquid crystal material. The photocurable liquid crystal material is a liquid crystal material which is cured by a photocrosslinking reaction when irradiated with light such as ultraviolet light. If the patterned retardation film 800 according to this exemplary embodiment is attached to the surface of a display screen such as an LCD, PDP, EL, or FED, a 3-D image display device can be formed. More specifically, when light emitted from the display screen is staggered by a series of first liquid crystal layer 832 and second liquid crystal layer 831 at different thicknesses, the light is retarded by a different phase. Therefore, the light system passing through the first liquid crystal layer 832 and the second liquid crystal layer 831 has different polarization characteristics. The viewer can use polarized glasses including two polarizing lenses corresponding to different polarizing features to recognize light of different characteristics with both eyes, and to sense 3-D images. In this case, the phase modulation characteristic of the light passing through the liquid crystal layer changes depending on the thickness of the liquid crystal layer and the optical anisotropy of the liquid crystal material, and the above Equation 1 shows the relationship.

The first liquid crystal layer 832 forming the liquid crystal material pattern layer 830 of the patterned retardation film 800 according to this embodiment can retard the optical phase (n-3/4) λ (n is a positive integer), and the second liquid crystal layer 831 The optical phase can be retarded (n-1/4) λ (n is a positive integer). In this case, one of the light components passing through the first liquid crystal layer 832 and the second liquid crystal layer 831 has a left circular polarization characteristic, and the other light component has a right circular polarization characteristic. The user can view high quality 3-D images using polarized glasses including a left eyeglass that selectively passes left circular polarization and a right eyeglass that selectively passes right circular polarized light. More specifically, if the optical anisotropy n of the liquid crystal material used is 0.17, in order to retard the optical phase with the first liquid crystal layer 832 by λ/4 (λ is here the wavelength of light, for example, λ/4 is 137.5 mm. And the optical phase retardation of the second liquid crystal layer 831 is 3λ/4 (λ is the wavelength of light, for example, 3λ/4 is 412.5 mm), and the thickness of the first liquid crystal layer 832 and the second liquid crystal layer 831 should each be 0.808 μm. With 2.426 microns. The thicknesses of the first liquid crystal layer 832 and the second liquid crystal layer 831 which form the liquid crystal material pattern layer 830 of the patterned retardation film 800 according to this embodiment must be precisely controlled to the micron or nanometer level. The thickness of the liquid crystal layer can be precisely controlled by a patterning method using a curable resin pattern layer having a fine pattern of micrometers or nanometers.

In the above description, the patterned retardation film according to another embodiment includes a plurality of grooves formed on the curable resin layer on the base member, a first liquid crystal layer partially corresponding to the groove, and the equivalent The second liquid crystal layer in the region above the interval between the grooves, but the invention is not limited thereto. In addition, it may allow various examples without departing from the gist of the present invention, as a patterned retardation sheet according to another embodiment of the present invention may have a plurality of grooves formed on one surface of the base member 1610, partially equivalent The first liquid crystal layer 1632 of the groove of the base member 1610 and the second liquid crystal layer 1631 corresponding to the upper portion of the space between the grooves of the base member 1610 are as shown in FIG.

A method of fabricating a patterned retarder in accordance with another exemplary embodiment of the present invention is described below.

Figure 16 shows a method of fabricating a patterned retarder in accordance with another illustrative embodiment of the present invention.

As shown in FIG. 16, a method of manufacturing a patterned retardation sheet according to another exemplary embodiment includes the steps of: coating a base member 800 with a curable resin (S1000); and forming a surface having a predetermined thickness therein. The plurality of imprinting masters 815 which are arranged in a pattern at predetermined intervals, harden and pressurize the applied curable resin to form a curable resin having a pattern in which a plurality of grooves 822 having a predetermined depth are arranged at predetermined intervals. a pattern layer 820 (S2000 and S3000); and a hardenable liquid crystal material is coated on the curable resin pattern layer 820 and hardened to form a liquid crystal material pattern layer 830 including the first liquid crystal layer 832 and the second liquid crystal layer 831 (S4000) ). In this case, the first liquid crystal layer 832 and the second liquid crystal layer 831 retard the optical phase differently. In addition, although not shown in FIG. 16, the method of fabricating the patterned retardation film according to the specific embodiment of the present invention may further include planarizing the liquid crystal material pattern layer using a CMP (Chemical Mechanical Polishing) device, and precisely controlling the first A step of thickness of a liquid crystal layer 832 and a second liquid crystal layer 831. In the method of manufacturing a patterned retardation film according to an exemplary embodiment of the present invention, the liquid crystal material may be filled using a spin coating method, a roll coating method, a dispensing coating method, or a gravure coating method. In this case, the liquid crystal material can be diluted in a polymer solvent. The method of coating the liquid crystal material is usually determined depending on the type of solvent or the dilution ratio. Further, the liquid crystal layer is formed by irradiating the filled liquid crystal material with light such as ultraviolet light and performing a photocrosslinking reaction. Therefore, the optical phase modulation characteristic of the liquid crystal layer changes depending on the thickness of the liquid crystal layer and the optical anisotropy of the liquid crystal material. The thickness of the liquid crystal layer is not particularly limited, but is preferably several micrometers or less.

Meanwhile, the step of producing a curable resin and the step of forming a curable resin pattern layer in the method of patterning the retardation sheet according to the specific embodiment of the present invention are carried out by imprinting. It is possible to use a flat plate compression molding method which uses a flat plate imprinting master that conforms to the material or shape of the base member. It is also possible to use a continuous roll method which uses a roll type imprinting master. In the case where the continuous roll method is used, the manufacturing method and the improved productivity can be simplified to form a large-scale fine curable resin pattern layer. More specifically, if the base member is a flexible film, the patterned retardation sheet according to the specific embodiment of the present invention can be manufactured by the roll method. In this case, the imprinting master may include a master roll, a die roll or a film forming die, as described in detail below.

Fig. 17 is a graph showing a first exemplary embodiment of a step of coating a curable resin and a step of forming a curable resin pattern layer in the method of manufacturing a patterned retardation sheet according to an exemplary embodiment of the present invention. As shown in Fig. 17, the first exemplary embodiment of the step of applying the curable resin and the step of forming the curable resin pattern layer uses the imprint master roll 940 as the imprint master. The imprint master roll 940 has a pattern in which a plurality of protrusions 942 having a predetermined height are arranged at predetermined intervals on a cylindrical metal surface, and is directly mounted on a manufacturing apparatus to be used. The curable resin pattern layer forming apparatus using the imprinting master roll 940 as an imprinting master mold includes a first roll 920 and a second roll 950 which support and drive the base member 910 on both sides. The film-type base member 910 is wound around the first roller 920, and the base member 912 on which the curable resin pattern layer is formed is wound around the second roller 950. It provides a guide roller 930a to 930d that transports the base member 910 between the first roller 920 and the second roller 950, and an imprint master roll 940 that forms a hardenable resin pattern layer on the base member 910. The portion in which the base member 910 is inserted into the imprinting master roll 940 has a curable resin injection tool 960 that provides a curable resin 962. Further, a hardening tool 970 that hardens the curable resin applied to the base member 910 is provided in the vicinity of the imprinting master roll 940. When the base member 910 is unwound from the first roller 920, the base member 910 is conveyed along the guide rollers 930a to 930d to contact the imprint master roll 940. In this case, the curable resin 962 is injected from the curable resin injection tool 960 to a portion where the base member 910 is inserted into the imprinting master roll 940. One surface of the base member 910 is closely attached to the surface of the imprinting master roll 940 on which the pattern is formed, so that the injected curable resin is arranged at a predetermined interval on the plurality of grooves 913 having a predetermined depth thereon. It is coated on the base member 910. The curable resin applied to the base member 910 is hardened by heat or ultraviolet light emitted from the hardening tool 970 provided near the imprinting master roll 940. In this case, the guide roller 930b in which the base member 910 is embedded on the imprinting master roll 940 is used to control the gap of the curable resin pattern layer formed on the base member 910. That is, if the guide roller 930b is pressed against the imprint master roll 940, the base member 910 thus presses the imprint master roll 940. Therefore, the thickness of the curable resin pattern layer formed becomes small. Conversely, if the guide roller 930 is separated from the imprint master roll 940, the gap between the base member 910 and the imprint master roll 940 becomes large. Therefore, a larger amount of the curable resin flows into the gap to cause an increase in the thickness of the curable resin pattern layer. The base member 912 on which the hardenable resin pattern layer (having a pattern in which the plurality of grooves 913 having a predetermined depth are arranged at predetermined intervals) is guided by the guide roller 930c while being passed through the imprinting master roll 940 The roller 940 is separated and then conveyed to wind the second roller 950.

In the method of manufacturing a patterned retardation sheet according to another exemplary embodiment of the present invention, the step of applying a curable resin and the second exemplary embodiment of the step of forming a curable resin pattern layer are performed by using an imprinting stamper roll. The first exemplary embodiment of the imprinted master roll is used as the imprint master. 18 is a second exemplary embodiment of an imprinting stamper roll for a step of coating a curable resin and a step of forming a curable resin pattern layer in a method of manufacturing a patterned retardation sheet according to an exemplary embodiment of the present invention. Cross section view. As shown in FIG. 18, it is provided with an imprinting stamper roller 1040 to closely fix a stamper 1041 having a pattern in which a plurality of projections 1042 having a predetermined height are arranged at predetermined intervals to one surface of the cylindrical stay 1044. The second exemplary embodiment of the step of applying the curable resin and the step of forming the curable resin pattern layer includes the steps of transporting the base member to be formed on the surface thereof, wherein the plurality of protrusions 1043 having a predetermined height are arranged at predetermined intervals a patterning stamper roll 1044; injecting a curable resin into a region in which one surface of the base member is in close contact with a pattern formed on a surface of the imprinting stamper roll 1044 to apply the curable resin Filling a surface of the base member with a pattern of the imprinting stamper 1044; contacting one surface of the base member in close contact with the surface of the imprinting stamper 1044 on which the pattern is formed, and hardening the curable resin Forming a curable resin pattern layer having a pattern in which a plurality of grooves having a predetermined depth are arranged at predetermined intervals, and attaching the curable resin pattern layer to one surface of the base member; and attaching the curable resin pattern thereon The base member of the layer is separated from the imprinting stamper 1044.

In the step of coating a curable resin and the step of forming a curable resin pattern layer in the method of manufacturing a patterned retardation sheet according to another embodiment, the first exemplary embodiment using an imprinting stamper as an imprinting master is used. The example has the advantage that the product quality is quite excellent. However, considering the productivity, the processing area of the pattern should be a large area of at least 500 mm or more, which causes a sharp increase in the cost of processing the pattern. In addition, it is difficult to handle due to its weight and volume. In addition, there may be partial contamination due to work errors caused during the manufacture of the product, or an increase in manufacturing cost due to the average life expectancy of repairing scratches and abrasion. Meanwhile, the second exemplary embodiment using the imprinting stamper as the imprinting master is complicated in manufacturing the stamper, and the manufacturing stamper is time-consuming to increase in size of the stamper, making it difficult to manufacture a stamper having a uniform thickness, and during processing. There is some problem in that the stamp cannot be recovered when the stamp is folded or deformed. Usually, the stamper is used for small flat type compression molding. According to the continuous roll method, if the stamper is attached to the support, the joint 1046a can be formed at both ends. It may have an irregular pattern at the junction or may result in a significant decrease in yield due to the short interval of irregular locations. In the process of producing a curable resin for patterning a retardation sheet and a process for forming a curable resin pattern layer, a problem may occur when an imprinting master roll or an imprinting stamper is used as an imprinting master, which can be used later in a A film-shaped forming mold in which a pattern in which a plurality of protrusions having a predetermined height are arranged at predetermined intervals is formed on the surface is overcome as an imprinting master.

Fig. 19 is a graph showing a third exemplary embodiment of a step of coating a curable resin and a step of forming a curable resin pattern layer in the method of manufacturing a patterned retardation sheet according to an exemplary embodiment of the present invention. The third exemplary embodiment shows the use of a film forming mold as an imprinting master. The curable resin pattern layer forming apparatus uses a film forming mold 1142 in which a pattern in which a plurality of protrusions 1144 having a predetermined height are arranged at predetermined intervals on one surface is used as an imprinting master. The curable resin pattern layer forming apparatus includes a first roll 1120 wound by the base member 1110 and a second roll 1150 wound by the base member 1112 on which the curable resin pattern layer is formed on both sides. Further, guide rollers 1130a to 1130e that transport the base member and the base member on which the curable resin pattern layer is formed are provided between the first roller 1120 and the second roller 1150. Further, the pattern molding unit 1140 which forms the curable resin pattern layer on the base member 1110 is disposed close to between the guide roller 1130c and the guide roller 1130d. The pattern molding unit 1140 includes a film-forming mold 1142 having a pattern, and the injected curable resin is pressed into a mold to form a curable resin pattern in accordance with the mold pattern, and the patterned curable resin is coated on the base member. Pattern roll 1445, and pattern guide rolls 1146a and 1146b for conveying the forming mold. The above-described molding die 1142 is formed by coating a pattern layer having a pattern on a film-type base member, and has a long strip shape. Although FIG. 19 shows only a portion of the pattern formed on the pattern layer of the forming mold, in practice, a pattern is formed on all of the forming molds. The forming die 1142 is formed such that the forming die covers the extension lines connecting the pattern roll 1145 and the pattern guide rolls 1146a and 1146b, and connects the both ends of the forming die. In this case, since the joints formed by the connection of the two ends of the pattern mold 1142 have a significantly longer interval than the joint surface of the stamper roll, the interval of the defective pattern generated at the joint surface is increased, which greatly improves the formation thereof. The yield of the base member 1112 of the entire hardenable resin pattern layer. In order to increase the spacing of the joints, a longer forming die 1142 can be formed, and the distance between the pattern roll 1145 and the pattern guide rolls 1146a and 1146b can be large. A portion of the base member 1110 inserted into the pattern molding unit 1140 is provided with a curable resin injection tool 1160 of an injection curable resin. Further, a hardening tool 1170 that irradiates heat or ultraviolet light to harden the curable resin is provided in a portion where the base member 1110 and the molding die 1142 move close to each other. However, in Fig. 19, the number of the guide rolls 1130a to 1130e and the pattern guide rolls 1146a and 1146b and their positions may be changed in accordance with the specific embodiment. The base member 1110 wound around the first roller 1120 is first conveyed by the guide rolls 1130a to 1130c. In this case, the forming mold 1142 of the pattern molding unit 1140 also moves and rotates by winding the pattern roll 1145 and the pattern guide rolls 1146a and 1146b. In this case, since the pattern roll 1145 is interlocked with the guide rolls 1130c and 1130d, the base member 1110 is guided by the guide rolls 1130c to interlock with the forming die 1142. Here, the guide roller 1130c performs a gap control function to control the thickness of the curable resin pattern layer formed on the base member. More specifically, if the guide roller 1130c is attached to the pattern roller 1145 in close proximity, a thin curable resin pattern layer can be formed. Conversely, if the guide roller 1130c is separated from the pattern roller, a thicker curable resin pattern layer can be formed. In addition to the distance between the guide roller 1130c and the pattern roller 1145, the thickness of the curable resin pattern layer can be adjusted by the viscosity of the curable resin, the patterning speed, and the tension of the base member. At the same time, in a portion where the guide roller 1130c and the pattern roller 1145 are interlocked, the curable resin is injected by the curable resin injection tool 1160 to be pressed and filled between the pattern of the base member 1110 and the molding die 1142, and the guide roller 1130c The pattern is uniformly dispersed by the pressure between the pattern roll 1145. The curable resin dispersed between the base member 1110 and the pattern of the forming mold 1142 is hardened by heat or ultraviolet light emitted from the hardening tool 1170. The base member on which the curable resin pattern layer is formed is taken out by the guide roller 1130d to be separated from the molding die 1142, and the base member 1112 on which the entire hardenable resin pattern layer is formed is conveyed by the guide roller 1130e to be wound up second. Roller 1150. The guide roller 1130d performs a separating function here to separate the base member 1112 on which the curable resin pattern layer is formed from the forming mold 1142. Further, although FIG. 19 shows only a part of the base member 1112 on which the curable resin pattern layer is formed, the base member 1112 on which the curable resin pattern layer is formed is also wound around the second roll 1150.

20 is a view showing another third exemplary embodiment of the step of coating a curable resin and the step of forming a curable resin pattern layer in the method of manufacturing a patterned retardation sheet according to another exemplary embodiment of the present invention. chart.

Another third exemplary embodiment shown in Fig. 20 is a modified embodiment of the pattern molding unit 440 shown in Fig. 8. Specifically, a film-shaped forming mold 1242 in which a pattern in which a plurality of protrusions 1244 having a predetermined height are arranged at predetermined intervals is formed on one surface is formed into a long roll shape having a length corresponding to the length of the base member 1210. Therefore, the base member 1212 on which the entire hard curable resin pattern layer is formed does not have a joint. Referring to Fig. 20, a curable resin pattern layer forming apparatus according to another third exemplary embodiment includes a first roll 1220 wound by a base member 1210 on both sides, and a substrate on which a curable resin pattern layer is formed. The second roller 1250 is wound by the member 1212. Further, guide rollers 1230a to 1230f that transport the base member and the base member on which the curable resin pattern layer is formed are provided between the first roller 1220 and the second roller 1250. Further, the pattern roll 1246 of the pattern molding unit 1240 which forms the curable resin pattern layer on the base member 1210 is disposed close to between the guide roller 1230c and the guide roller 1230d. The number and position of the guide rollers 1230a to 1230f can be modified here in accordance with the specific embodiment. The pattern molding unit 1240 includes a film-forming mold 1242 having a pattern, a third roller 1245 wound by the mold, pressing the injected curable resin into a mold to form a curable resin pattern in accordance with the mold pattern, and The patterned curable resin is applied to the pattern roll 1246 on the base member 1210, the pattern guide rolls 1247a to 1247d of the forming mold, and the fourth roll 1248 wound by the conveyed forming mold. The number and position of the pattern guide rollers 1247a to 1247d can be modified in accordance with the specific embodiment. The difference from the embodiment shown in Fig. 19 is that the forming die is conveyed by the pattern roll 1246 and the pattern guide rolls 1247a to 1247d to wind the third roll 1245, and the base member 1210 is formed of a curable resin. The pattern layer is then wound around a fourth roll 1248. In this case, the forming mold 1242 can be formed to have the same length as the base member 1210. Thus, a pattern can be uniformly formed on all of the base members 1212 on which the curable resin pattern layer is formed, but no defective pattern or discontinuous pattern due to the joint faces is generated. Although FIG. 20 shows only a portion of the pattern formed on the pattern layer of the forming mold, in practice, a pattern is formed on all of the forming molds. It provides a curable resin injection tool 1260 that injects a curable resin in a portion where the base member 1210 is inserted into the pattern molding unit 1240 (i.e., the guide roller 1230c is closely attached to the pattern roller 1246). Further, a hardening tool 1270 that irradiates heat or ultraviolet light to harden the curable resin is provided in a portion where the base member and the forming mold 1242 move close to each other. The base member 1210 wound around the first roller 1220 is first conveyed by the guide rollers 1230a to 1230c to be inserted into the portion where the guide roller 1230c and the pattern roller 1246 are interlocked. In this case, the forming mold 1242 of the pattern molding unit 1240 is also unwound from the third roller 1245, and then conveyed between the insertion pattern roller 1246 and the guide roller 1230c by the pattern guide roller 1247a to be closely attached to the base member 1210. Here, the guide roller 1230c performs a gap control function to control the thickness of the curable resin pattern layer formed on one surface of the base member. At the same time, since the curable resin is injected into the portion between the guide roller 1230c and the pattern roller 1246 (inserted into the base member 1210) by the curable resin injection tool 1260, the curable resin is patterned on one surface of the base member and the molding die 1242. The rolling and filling are performed, and uniformly dispersed by the pressure between the guide roller 1230c and the pattern roller 1246, and then hardened by heat or ultraviolet light emitted from the hardening tool 1270. Therefore, the base member 1210 is coated with a patterned curable resin. The base member on which the curable resin pattern layer is formed is conveyed by the guide rolls 1230d and the guide rolls 1230e, and the forming mold 1242 is also conveyed by the guide rolls 1230d and the pattern guide rolls 1247b. Therefore, the base member and the molding die 1242 on which the curable resin pattern layer is formed are attached between the guide roller 1230d and the guide roller 1230e, or are closely attached and conveyed between the guide roller 1230d and the pattern guide roller 1247b. Then, the base member 1212 on which the curable resin pattern layer is formed is guided and conveyed by the guide roller 1230f to wind the second roller 1250. Further, the forming die 1242 is guided and conveyed by the pattern guide rolls 1247c and 1247d to wind the fourth roll 1248. The guide roller 1230e and the pattern guide roller 1247b each perform a separating function to separate the base member 1212 on which the curable resin pattern layer is formed from the molding die 1242. Meanwhile, as described above, if the length of the forming mold 1242 is equal to the length of the base member 1210, the curable resin pattern layer can be formed on all of the base members 1210 until the forming mold is unwound from the third roller 1245, and then re-wound Four rolls 1248. As a result, a defective pattern due to the joint was not generated on the base member on which the curable resin pattern layer was formed. Further, although FIG. 20 shows only a part of the base member 1212 on which the curable resin pattern layer is formed, the base member 1212 on which the curable resin pattern layer is formed is actually wound around the second roll 1250.

Figure 21 is a view showing a step of coating a curable resin and a step of forming a curable resin pattern layer in a third exemplary embodiment of the method for forming a patterned retardation film according to an exemplary embodiment of the present invention. Cross-sectional view, Fig. 22 is a cross-sectional view of another forming mold, and Fig. 23 is a cross-sectional view of still another forming mold. The film forming molds used in Figs. 19 and 20 are patterned on the curable resin injected by the curable resin injection tool, and are formed into a flexible film shape in which a pattern is formed on the polymer resin. Specifically, as shown in FIGS. 21 to 23, the forming mold 1342, 1442 or 1542 has a two-layer structure including a base member layer 1342a, 1442a or 1542a having a substantially uniform continuous flat surface, and a base member layer. A pattern layer 1342b, 1442b or 1542b formed on one surface and having a pattern in which a plurality of protrusions having a predetermined height are arranged at predetermined intervals. Further, a forming die may be formed on the other surface of the base member layer, as shown in FIGS. 22 and 23, and may further include a friction unit 1442c or 1542c that increases friction against the surface of the roller. The material for the base member layer of the forming mold may be a film which is transparent, flexible, and has predetermined tensile strength and durability. Specifically, a PET film is preferred. Further, the resin material forming the pattern layer may be a mixture of a polymer material such as an oligomer or a curable primer. An example of a method of manufacturing a forming mold will be described below. First, a metal or film master is fixed, and then the master mold is coated with a molded polymer resin. Next, after the base member film for a molding die is overlaid on the master mold on which the polymer resin is applied, the cylindrical roller moves through the base member film to uniformly apply a predetermined pressure. In this case, the applied polymer resin is rolled and filled between the patterns of the master mold, and then uniformly dispersed by a predetermined thickness due to the pressure of the guide rolls. Next, the resin is filled in a contact state between the master mold and the base member film in accordance with the properties of the resin, the resin is hardened by irradiation of heat or ultraviolet light, and then the base member film is separated from the master mold. As for the base member film, if necessary, a base member film which is surface-trimmed to have adhesion to the molded polymer resin can be used. The forming mold can be produced by various methods other than the above manufacturing methods. At the same time, as shown in FIGS. 19 and 20, when the forming mold is mounted on the pattern roll and the pattern guide roll, the forming mold is closely fixed to the pattern roll and the pattern guide roll to form and form on the surface of the pattern roll or the pattern guide roll. It is important to have no air bubbles between the molds or to accumulate foreign matter. In this case, in order to improve the workability, the bubbles may be dissipated over time by forming small holes at regular intervals on the surface of the pattern roll or the pattern guide roll. Further, when driving the device for forming a curable resin pattern layer, in order to reduce the bad pattern of the base member in which the entire curable resin pattern layer is formed and to improve the quality thereof, it is necessary to prevent the surface of the pattern roll and the pattern guide roll from forming the mold. Sliding between. Therefore, as shown in Figs. 22 and 23, it is preferable to form a friction unit on the other surface of the base member layer of the forming mold. The forming die 1442 shown in Fig. 22 includes a plurality of micron-thick convex faces 1442c formed on the bottom of the base member layer 1442a. Thus, the high frictional force between the surface of the pattern roll or pattern guide roll and the convex surface of the forming mold prevents the forming mold from slipping. In this case, the convex surface 1442c may be made of an elastic material such as rubber or polyfluorene. Further, the forming die 1542 shown in Fig. 23 includes a film 1542c formed on the bottom of the base member layer 1542a to increase the friction against the surface of the pattern roll or the pattern guide roll. In this case, the film 1542c may also be made of an elastic material such as rubber or polyfluorene. Meanwhile, in addition to the above examples, various modifications/embodiments to prevent the sliding of the forming mold may be possible.

In the above description of the method of manufacturing the patterned retardation sheet according to the exemplary embodiment, the curable resin applied to the base member is formed on one surface in a pattern in which a plurality of protrusions having a predetermined thickness are arranged at predetermined intervals The imprinting master mold is pressed and hardened to form a curable resin pattern layer having a pattern in which a plurality of grooves having a predetermined depth are arranged at predetermined intervals, but the invention is not limited thereto. The method of manufacturing a patterned retardation sheet according to this exemplary embodiment may include the steps of: after applying heat to the base member, using a mold in which a pattern in which a plurality of protrusions having a predetermined thickness are arranged at predetermined intervals is formed on one surface The base member is pressurized, and a pattern in which a plurality of grooves having a predetermined depth are arranged at predetermined intervals is formed on the base member, or a pattern in which a plurality of protrusions having a predetermined height are arranged at a predetermined interval is formed on one surface. After the mold is applied with heat, the base member is pressurized with the mold, and a pattern in which a plurality of grooves having a predetermined depth are arranged at predetermined intervals is formed on the base member. Therefore, the exemplary embodiments can be modified in various ways without departing from the gist of the invention.

As described above, the specific embodiments have been illustrated and exemplified in the drawings and the specification. The exemplified embodiments are chosen and described in order to explain certain embodiments of the invention, It is apparent from the above description that certain aspects of the invention are not limited by the specific details of the embodiments described herein, and that other modifications and applications or equivalents may be made by those skilled in the art. Numerous variations, modifications, changes, and other uses and applications of the present invention will become apparent to those skilled in the art. All such changes, modifications, variations, and other uses and applications are intended to be covered by the present invention, and are only limited by the scope of the following claims.

10. . . Base member

20. . . Photocurable liquid crystal material

30. . . First liquid crystal material pattern layer

40. . . Photocurable liquid crystal material

50. . . Second liquid crystal material layer

100. . . Patterned hysteresis

110. . . Base member

115. . . Engraved master

116. . . First prominent

117. . . Second prominent

120. . . Curable resin pattern layer

121. . . First slot

122. . . Second slot

130. . . Liquid crystal material pattern layer

131. . . First liquid crystal layer

132. . . Second liquid crystal layer

210. . . Base member

212. . . a base member on which a curable resin pattern layer is formed

213. . . First slot

214. . . Second slot

220. . . First roller

230a. . . Guide rollers

230b. . . Guide rollers

230c. . . Guide rollers

230d. . . Guide rollers

240. . . Engraved master roll

241. . . First prominent

242. . . Second prominent

250. . . Second roller

260. . . Curing resin injection tool

262. . . Curable resin

270. . . Hardening tool

340. . . Imprinting die roll

341. . . stamper

342. . . First prominent

343. . . Second prominent

344. . . Cylindrical support

346a. . . Junction

410. . . Base member

412. . . a base member on which a curable resin pattern layer is formed

420. . . First roller

430a. . . Guide rollers

430b. . . Guide rollers

430c. . . Guide rollers

430d. . . Guide rollers

430e. . . Guide rollers

440. . . Pattern molding unit

442. . . Forming mold

442a. . . Base member layer

442b. . . Pattern layer

443. . . First prominent

444. . . Second prominent

445. . . Pattern roll

446a. . . Pattern guide roller

446b. . . Pattern guide roller

450. . . Second roller

460. . . Curing resin injection tool

470. . . Hardening tool

510. . . Base member

512. . . a base member on which a curable resin pattern layer is formed

520. . . First roller

530a. . . Guide rollers

530b. . . Guide rollers

530c. . . Guide rollers

530d. . . Guide rollers

530e. . . Guide rollers

530f. . . Guide rollers

540. . . Pattern molding unit

542. . . Film forming mold

543. . . First prominent

544. . . Second prominent

545. . . Third roll

546. . . Pattern roll

547a. . . Pattern guide roller

547b. . . Pattern guide roller

547c. . . Pattern guide roller

547d. . . Pattern guide roller

548. . . Fourth roller

550. . . Second roller

560. . . Curing resin injection tool

570. . . Hardening tool

642. . . Forming mold

642a. . . Base member layer

642b. . . Pattern layer

642c. . . Friction unit

742. . . Forming mold

742a. . . Base member layer

742b. . . Pattern layer

742c. . . Friction unit

800. . . Patterned hysteresis

810. . . Base member

815. . . Engraved master

817. . . protruding

820. . . Curable resin pattern layer

822. . . groove

830. . . Liquid crystal material pattern layer

831. . . Second liquid crystal layer

832. . . First liquid crystal layer

910. . . Base member

912. . . a base member on which a curable resin pattern layer is formed

913. . . groove

920. . . First roller

930a. . . Guide rollers

930b. . . Guide rollers

930c. . . Guide rollers

930d. . . Guide rollers

940. . . Engraved master roll

942. . . protruding

950. . . Second roller

960. . . Curing resin injection tool

962. . . Curable resin

970. . . Hardening tool

1040. . . Imprinting die roll

1041. . . stamper

1042. . . protruding

1043. . . protruding

1044. . . Imprinting die roll

1046a. . . Junction

1110. . . Base member

1112. . . a base member on which a curable resin pattern layer is formed

1120. . . First roller

1130a. . . Guide rollers

1130b. . . Guide rollers

1130c. . . Guide rollers

1130d. . . Guide rollers

1130e. . . Guide rollers

1140. . . Pattern molding unit

1142. . . Film forming mold

1144. . . protruding

1145. . . Pattern roll

1146a. . . Pattern guide roller

1146b. . . Pattern guide roller

1146c. . . Pattern guide roller

1146d. . . Pattern guide roller

1150. . . Second roller

1160. . . Curing resin injection tool

1170. . . Hardening tool

1210. . . Base member

1212. . . a base member on which a curable resin pattern layer is formed

1220. . . First roller

1230a. . . Guide rollers

1230b. . . Guide rollers

1230c. . . Guide rollers

1230d. . . Guide rollers

1230e. . . Guide rollers

1230f. . . Guide rollers

1240. . . Pattern molding unit

1242. . . Film forming mold

1244. . . protruding

1245. . . Third roll

1246. . . Pattern roll

1247a. . . Pattern guide roller

1247b. . . Pattern guide roller

1247c. . . Pattern guide roller

1247d. . . Pattern guide roller

1248. . . Fourth roller

1250. . . Second roller

1260. . . Curing resin injection tool

1270. . . Hardening tool

1342. . . Forming mold

1342a. . . Base member layer

1342b. . . Pattern layer

1442. . . Forming mold

1442a. . . Base member layer

1442b. . . Pattern layer

1442c. . . Friction unit

1542. . . Forming mold

1542a. . . Base member layer

1542b. . . Pattern layer

1542c. . . Friction unit

1610. . . Base member

1631. . . Second liquid crystal layer

1632. . . First liquid crystal layer

FIG. 1 is a view describing a method of manufacturing a patterned retardation film according to the related art.

2 is a front elevational view of a patterned retarder in accordance with an exemplary embodiment of the present invention.

3 is an exploded cross-sectional view of a patterned retarder in accordance with an exemplary embodiment of the present invention.

4 is a combined cutaway view of a patterned retarder in accordance with an exemplary embodiment of the present invention.

Figure 5 is a diagram showing a method of fabricating a patterned retardation film in accordance with an exemplary embodiment of the present invention.

Fig. 6 is a view showing a first exemplary embodiment of a step of coating a curable resin and a step of forming a curable resin pattern layer in the method of manufacturing a patterned retardation sheet according to an exemplary embodiment of the present invention.

Figure 7 is a plan view showing a second exemplary embodiment of a step of coating a curable resin and a step of forming a curable resin pattern layer in a method of fabricating a patterned retardation film according to an exemplary embodiment of the present invention. Cross-sectional view of the die roll.

Fig. 8 is a view showing a third exemplary embodiment of a step of applying a curable resin and a step of forming a curable resin pattern layer in the method of manufacturing a patterned retardation sheet according to an exemplary embodiment of the present invention.

Figure 9 is a view showing another third exemplary embodiment of the step of applying a curable resin and the step of forming a curable resin pattern layer in the method of manufacturing a patterned retardation sheet according to an exemplary embodiment of the present invention. .

Figure 10 is a view showing a third exemplary embodiment of a step of coating a curable resin and a step of forming a curable resin pattern layer in a method of manufacturing a patterned retardation sheet according to an exemplary embodiment of the present invention. Cross section view.

Figure 11 is a cross-sectional view of another forming mold.

Figure 12 is a cross-sectional view of still another forming die.

Figure 13 is a front elevational view of a patterned retarder in accordance with an exemplary embodiment of the present invention.

Figure 14 is an exploded cross-sectional view of a patterned retarder in accordance with an exemplary embodiment of the present invention.

Figure 15 is a cross-sectional view showing the combination of patterned retarded sheets in accordance with an exemplary embodiment of the present invention.

Figure 16 shows a method of fabricating a patterned retarder in accordance with another illustrative embodiment of the present invention.

Figure 17 is a view showing a first exemplary embodiment of a step of coating a curable resin and a step of forming a curable resin pattern layer in a method of manufacturing a patterned retardation sheet according to another exemplary embodiment of the present invention.

Figure 18 is an illustration of a second exemplary embodiment of a step of coating a curable resin and a step of forming a curable resin pattern layer in a method of fabricating a patterned retardation film according to another exemplary embodiment of the present invention. Cross-sectional view of the stamper roll.

Fig. 19 is a view showing a third exemplary embodiment of a step of applying a curable resin and a step of forming a curable resin pattern layer in the method of manufacturing a patterned retardation sheet according to another exemplary embodiment of the present invention.

20 is another third exemplary embodiment of a step for coating a curable resin and a step of forming a curable resin pattern layer in a method of manufacturing a patterned retardation sheet according to another exemplary embodiment of the present invention. Figure.

Figure 21 is a view showing a third exemplary embodiment of a step of coating a curable resin and a step of forming a curable resin pattern layer in a method of manufacturing a patterned retardation sheet according to another exemplary embodiment of the present invention. A cross-sectional view of a mold.

Figure 22 is a cross-sectional view of another forming mold.

Figure 23 is a cross-sectional view of still another forming die.

Figure 24 is a cross-sectional view showing a combination of patterned retarded sheets in accordance with another exemplary embodiment of the present invention.

It is understood that the appended drawings are not necessarily to scale, The design features of the invention disclosed below, including, for example, the specified dimensions, orientations, positions, and shapes, are determined in part by the particular intended application and use environment. In addition, a detailed description of the related art is omitted in the description of the present invention if the detailed description of the configuration or function of the related art does not necessarily deviate from the gist of the present invention. The above is a description of preferred embodiments of the invention. However, the technical concept is not limited thereto, but can be modified or implemented by those skilled in the art.

The number in the figures indicates the same or equivalent parts of the invention in the figures.

100. . . Patterned hysteresis

110. . . Base member

120. . . Curable resin pattern layer

130. . . Liquid crystal material pattern layer

131. . . First liquid crystal layer

132. . . Second liquid crystal layer

Claims (50)

A patterned retardation sheet comprising: a base member; a curable resin pattern layer formed of a curable resin coated on the base member, and having a first groove and a second portion having different depths therein a pattern in which the grooves are alternately arranged; and a liquid crystal material pattern layer including the first liquid crystal layer and the second liquid crystal layer formed of the curable liquid crystal material accommodated in the first and second grooves of the curable resin pattern layer Wherein the first liquid crystal layer and the second liquid crystal layer retard the optical phase differently. A patterned retardation sheet comprising: a base member; a curable resin pattern layer formed of a curable resin coated on the base member, and having a plurality of grooves having a predetermined depth therein at predetermined intervals a pattern of alignment; and a liquid crystal material pattern layer comprising a first liquid crystal layer and a second liquid crystal layer having different thicknesses formed by a liquid crystal material coated on the curable resin pattern layer, wherein a portion of the first liquid crystal layer is Corresponding to the groove, the second liquid crystal layer corresponds to a region on the groove interval, and the first liquid crystal layer and the second liquid crystal layer retard the optical phase differently. The patterned retardation sheet of claim 2, wherein the first liquid crystal layer is formed of a curable liquid crystal material coated on an inner region of the groove, and the second liquid crystal layer is coated in a space region of the groove. Formed on the hard curable liquid crystal material. The patterned retardation sheet of claim 1 or 2, wherein the base member is a transparent member. The patterned retardation sheet of claim 4, wherein the transparent member is a glass member. The patterned retardation sheet of claim 1 or 2, wherein the base member is a flexible film. The patterned retardation sheet of claim 1 or 2, wherein the curable resin is a thermosetting resin or a photocurable resin. The patterned retardation sheet of claim 7, wherein the photocurable resin is an ultraviolet curable resin. The patterned retardation sheet of claim 1 or 2, wherein the liquid crystal material is a photocurable liquid crystal material. The patterned retardation sheet of claim 9, wherein the photocurable liquid crystal material is an ultraviolet curable liquid crystal material. The patterned retardation film of claim 1 or 2, wherein the first liquid crystal layer has an optical phase retardation (n-3/4) λ, and the second liquid crystal layer has a light phase retardation (n-1/4) λ, and n are positive integers. The patterned retardation sheet of claim 11, wherein one of the light components passing through the first liquid crystal layer and the second liquid crystal layer has a left circular polarization characteristic, and the other light component has a right circular polarization characteristic. A method of manufacturing a patterned retardation sheet, comprising: coating a base member with a curable resin; and using an imprint master mold formed on one surface thereof in a pattern in which a first protrusion and a second protrusion having different heights are alternately arranged, Pressurizing and hardening the applied curable resin to form a curable resin pattern layer having a pattern in which first grooves and second grooves having different depths are alternately arranged; and filling the curable liquid crystal material to the hardenability Forming a liquid crystal material pattern layer including a first liquid crystal layer and a second liquid crystal layer in a first groove and a second groove of the resin pattern layer, wherein the first liquid crystal layer and the second liquid crystal layer have different optical phases Hysteresis. A method of producing a patterned retardation sheet, comprising: coating a base member with a curable resin; using an imprint master mold formed on one surface thereof in a pattern in which a plurality of protrusions having a predetermined thickness are arranged at predetermined intervals, to be coated The curable resin is pressurized and hardened to form a plurality of grooves having a predetermined depth therein a curable resin pattern layer having a pattern arranged at a predetermined interval; and applying a curable liquid crystal material to the curable resin pattern layer and curing, thereby forming a liquid crystal material pattern layer including a first liquid crystal layer and a second liquid crystal layer having different thicknesses, The first liquid crystal layer corresponds to the groove, and the second liquid crystal layer corresponds to the interval between the grooves, and the first liquid crystal layer and the second liquid crystal layer retard the optical phase differently. The method of claim 13 or 14, wherein the base member is a transparent member. The method of claim 15, wherein the transparent member is a glass member. The method of claim 13 or 14, wherein the base member is a flexible film. The method of claim 13, wherein the base member is a flexible film, and coating the curable resin and forming the curable resin pattern layer comprises: transporting the base member to a surface formed thereon having a different height An imprinting master roll having a pattern in which the first protrusion and the second protrusion are alternately arranged; injecting the curable resin into an area in which one surface of the base member closely contacts the pattern formed on the surface of the imprinting master roll Filling a surface of the base member with a pattern of the imprinted master roll; the surface of the base member is in close contact with the surface of the imprinted master roll on which the pattern is formed, and Curing the curable resin to form a curable resin pattern layer having a pattern in which first grooves and second grooves having different depths are alternately arranged, and attaching the curable resin pattern layer to one surface of the base member; And separating the base member to which the curable resin pattern layer is attached from the imprinting master roll, and the imprinting master roll has a cylindrical metal Wherein the surface of the formed protrusion height different from the first and second projections are arranged in the staggered pattern. The method of claim 13, wherein the base member is a flexible film, and coating the curable resin and forming the curable resin pattern layer comprises: transporting the base member to a surface formed thereon having a different height An imprinting stamping roll having a first protruding pattern and a second protruding staggered pattern; injecting a curable resin into an area in which one surface of the base member is in close contact with a pattern formed on a surface of the imprinting stamping roll Filling the surface of the base member with the surface of the imprinting stamper with the curable resin; contacting one surface of the base member in close contact with the surface of the imprinting stamper on which the pattern is formed, and Curing the curable resin to form a curable resin pattern layer having a pattern in which first grooves and second grooves having different depths are alternately arranged, and attaching the curable resin pattern layer to one surface of the base member; And separating the base member to which the curable resin pattern layer is attached from the imprinting stamper roll, and the imprinting stamper roller has a close proximity to the stamping roller Cylindrical support surface, which has a height different from the first stamper and the second protrusion arranged alternately projecting the pattern. The method of claim 13, wherein the base member is a flexible film, and coating the curable resin and forming the curable resin pattern layer comprises: conveying the base member to the pattern roll using a guide roller; using the pattern guide roller A film forming mold in which a pattern in which the first protrusions and the second protrusions having different heights are alternately arranged is conveyed on the surface thereof to the pattern roll; the curable resin is injected to a surface in which the base member is attached close to In a region of the pattern formed on one surface of the forming mold, the curable resin is filled between one surface of the base member and the pattern of the forming mold; and one surface of the base member is attached to the surface The surface of the molding die on which the pattern is formed, and the curable resin is cured to form a curable resin pattern layer having a pattern in which first grooves and second grooves having different depths are alternately arranged, and the curable resin is used. a pattern layer attached to one surface of the base member; and the base member to which the curable resin pattern layer is attached is formed from the surface With separation. The method of claim 20, wherein the film forming mold comprises: a film type base member layer; and a surface formed on one surface of the base member layer, and having a first protrusion and a height different in height A pattern layer that protrudes in a pattern that is alternately arranged. The method of claim 21, wherein the film forming mold further comprises: a friction unit formed on the other surface of the base member layer and adding a frictional force to the surface of the roller. The method of claim 22, wherein the base member layer is formed of a PET film. The method of claim 22, wherein the pattern layer is formed of a polymer resin. The method of claim 22, wherein the friction unit is formed by a plurality of fine convex surfaces. The method of claim 22, wherein the friction unit comprises a film formed of an elastic material. The method of claim 14, wherein the base member is a flexible film, and coating the curable resin and forming the curable resin pattern layer comprises: conveying the base member to be formed on one surface thereof and having a predetermined An engraved master roll that protrudes at a predetermined interval; the curable resin is injected into an area in which a surface of the base member is closely attached to a pattern formed on one surface of the imprinting master roll Filling a surface of the base member with a pattern of the imprinting master roll; and attaching one surface of the base member to the surface of the imprinting master roll on which the pattern is formed, and Curing the curable resin to form a curable resin pattern layer having a pattern in which a plurality of grooves having a predetermined depth are arranged at predetermined intervals, and attaching the curable resin pattern layer to one surface of the base member; and The base member to which the curable resin pattern layer is attached is separated from the forming mold, and the imprinting master roll is tied to a cylindrical gold Wherein a plurality of surface protrusions having a predetermined height are formed of patterns arranged at predetermined intervals. The method of claim 14, wherein the base member is a flexible film, and coating the curable resin and forming the curable resin pattern layer comprises: conveying the base member to be formed on one surface thereof and having a predetermined An engraved stamper roll that protrudes at a predetermined interval in a plurality of heights; the curable resin is injected into an area in which a surface of the base member is closely attached to a pattern formed on one surface of the imprinting stamper roll Filling a surface of the base member with a pattern of the imprinting stamper; and attaching one surface of the base member to the surface of the imprinting stamper on which the pattern is formed, and Curing the curable resin to form a curable resin pattern layer having a pattern in which a plurality of grooves having a predetermined depth are arranged at predetermined intervals, and attaching the curable resin pattern layer to one surface of the base member; and The base member to which the curable resin pattern layer is attached is separated from the forming mold, and the imprinting stamping roll system will have A plurality of projections having a predetermined height is fixed close to the cylindrical surface of the supporting body are arranged and formed in a predetermined interval of the stamper. The method of claim 14, wherein the base member is a flexible film, and coating the curable resin and forming the curable resin pattern layer comprises: conveying the base member to the pattern roll using a guide roller; using the pattern guide roller A film-shaped forming mold in which a pattern in which a plurality of protrusions having a predetermined height are arranged at a predetermined interval is formed on a surface thereof is fed to a pattern roll; and a curable resin is injected thereto in which one surface of the base member is closely attached to the forming a region of the pattern formed on one surface of the mold, wherein the curable resin is filled between a surface of the base member and a pattern of the forming mold; and a surface of the base member is attached thereto to be closely attached thereto Patterning the surface of the molding die, and curing the curable resin to form a curable resin pattern layer having a pattern in which a plurality of grooves having a predetermined depth are arranged at predetermined intervals, and attaching the curable resin pattern layer to the substrate a surface of the member; and the base member to which the curable resin pattern layer is attached from the molding die Separation. The method of claim 29, wherein the film forming mold comprises: a film type base member layer; and formed on one surface of the base member layer, and having a plurality of protrusions having a predetermined thickness therein A pattern layer of spaced patterns. The method of claim 30, wherein the film forming mold further comprises: a friction unit formed on the other surface of the base member layer and adding friction to the surface of the roller. The method of claim 30, wherein the base member layer is formed of a PET film. The method of claim 30, wherein the pattern layer is formed of a polymer resin. The method of claim 31, wherein the friction unit is formed by a plurality of fine convex surfaces. The method of claim 31, wherein the friction unit comprises a film formed of an elastic material. The method of any one of claims 13, 14, 16, and 18 to 35, further comprising: planarizing the liquid crystal material pattern layer. The method of any one of claims 13, 14, 16, and 18 to 35, wherein the curable resin is a thermosetting resin or a photocurable resin. The method of claim 37, wherein the photocurable resin is an ultraviolet curable resin. The method of any one of claims 13, 14, 16, and 18 to 35, wherein the curable liquid crystal material is a photocurable liquid crystal material. The method of claim 39, wherein the photocurable liquid crystal material is an ultraviolet curable liquid crystal material. The method of any one of claims 13, 14, 16, and 18 to 35, wherein the first liquid crystal layer has an optical phase retardation (n-3/4) λ, and the second liquid crystal layer is light Phase hysteresis (n-1/4) λ, and n is a positive integer. The method of claim 41, wherein one of the light components passing through the first liquid crystal layer and the second liquid crystal layer has a left circular polarization characteristic, and the other light component has a right circular polarization characteristic. A patterned retardation sheet comprising: a base member having a pattern in which first grooves and second grooves having different depths are alternately arranged; and a liquid crystal material pattern layer included in the base member The first liquid crystal layer and the second liquid crystal layer formed by the first and second grooves of the curable liquid crystal material, wherein the first liquid crystal layer and the second liquid crystal layer retard the optical phase differently. A patterned retardation sheet comprising: a base member having a pattern in which a plurality of grooves having a predetermined depth are arranged at predetermined intervals; and a liquid crystal material pattern layer including a first groove coated on the base member a first liquid crystal layer and a second liquid crystal layer having a thickness different from that formed by the curable liquid crystal material of the second trench, wherein one portion of the first liquid crystal layer corresponds to the groove, and the second liquid crystal layer corresponds to between the grooves The region above the interval, and the first liquid crystal layer and the second liquid crystal layer retard the optical phase differently. A patterned retardation film according to claim 43 or 44, wherein the first liquid crystal layer has an optical phase retardation (n-3/4) λ, and the second liquid crystal layer has a light phase retardation (n-1/4) λ, and n are positive integers. A method of manufacturing a patterned retardation sheet, comprising: applying heat to a base member; and adding the base member to a mold formed on one surface thereof in a pattern in which first and second protrusions of different heights are alternately arranged Pressing, forming a pattern in which the first grooves and the second grooves having different depths are alternately arranged on the base member; and filling the first and second grooves with the curable liquid crystal material, and then pressing the hardenable liquid crystal The material is hardened to form a liquid crystal material pattern layer including the first liquid crystal layer and the second liquid crystal layer, wherein the first liquid crystal layer and the second liquid crystal layer retard the optical phase differently. A method of manufacturing a patterned retardation sheet, comprising: preparing a base member; preparing a mold on a surface in which a pattern in which first and second protrusions having different heights are alternately arranged is formed; after heat is applied to the mold Pressing the base member with the mold, and forming a pattern in which the first grooves and the second grooves having different depths are alternately arranged on the base member; and filling the first and second grooves with the curable liquid crystal material The hard curable liquid crystal material is hardened in the groove to form a liquid crystal material pattern layer including the first liquid crystal layer and the second liquid crystal layer, wherein the first liquid crystal layer and the second liquid crystal layer retard the optical phase differently. A method of manufacturing a patterned retardation sheet, comprising: applying heat to a base member; pressurizing the base member using a mold in which a pattern in which a plurality of protrusions having a predetermined thickness are arranged at a predetermined interval is formed on one surface, Forming a pattern in which a plurality of grooves having a predetermined depth are arranged at predetermined intervals; and coating the base member having the groove with a hardenable liquid crystal material and hardening to form a liquid crystal including the first liquid crystal layer and the second liquid crystal layer; The material pattern layer, wherein the first liquid crystal layer corresponds to the groove, the second liquid crystal layer corresponds to the interval of the groove, and the first liquid crystal layer and the second liquid crystal layer retard the optical phase differently. A method of manufacturing a patterned retardation sheet, comprising: preparing a base member; preparing a mold on a surface in which a pattern of a plurality of protrusions having a predetermined thickness is arranged at a predetermined interval; after applying heat to the mold, using the mold The mold presses the base member, and a pattern in which a plurality of grooves having a predetermined depth are arranged at predetermined intervals is formed on the base member; and the base member having the groove is coated with a curable liquid crystal material and the curable liquid crystal material is coated Hardening, forming a liquid crystal material pattern layer including a first liquid crystal layer and a second liquid crystal layer, wherein the first liquid crystal layer corresponds to the groove, the second liquid crystal layer corresponds to the space of the groove, and the first liquid crystal layer and the first The two liquid crystal layers retard the optical phase differently. The patterned retardation sheet of any one of claims 46 to 49, wherein the first liquid crystal layer has an optical phase retardation (n-3/4) λ, and the second liquid crystal layer retards the optical phase (n -1/4) λ, and n is a positive integer.