WO2005003822A1 - Film optique microstructure et procede de production associe - Google Patents

Film optique microstructure et procede de production associe Download PDF

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Publication number
WO2005003822A1
WO2005003822A1 PCT/US2004/012267 US2004012267W WO2005003822A1 WO 2005003822 A1 WO2005003822 A1 WO 2005003822A1 US 2004012267 W US2004012267 W US 2004012267W WO 2005003822 A1 WO2005003822 A1 WO 2005003822A1
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WO
WIPO (PCT)
Prior art keywords
optical film
film
substrate
image display
microstructures
Prior art date
Application number
PCT/US2004/012267
Other languages
English (en)
Inventor
Koichi Sano
Original Assignee
3M Innovative Properties Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 3M Innovative Properties Company filed Critical 3M Innovative Properties Company
Priority to AU2004254901A priority Critical patent/AU2004254901A1/en
Priority to US10/559,521 priority patent/US20060132945A1/en
Priority to EP04750422A priority patent/EP1631847A1/fr
Publication of WO2005003822A1 publication Critical patent/WO2005003822A1/fr

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Classifications

    • GPHYSICS
    • G06COMPUTING; CALCULATING OR COUNTING
    • G06FELECTRIC DIGITAL DATA PROCESSING
    • G06F3/00Input arrangements for transferring data to be processed into a form capable of being handled by the computer; Output arrangements for transferring data from processing unit to output unit, e.g. interface arrangements
    • G06F3/01Input arrangements or combined input and output arrangements for interaction between user and computer
    • G06F3/048Interaction techniques based on graphical user interfaces [GUI]
    • G06F3/0487Interaction techniques based on graphical user interfaces [GUI] using specific features provided by the input device, e.g. functions controlled by the rotation of a mouse with dual sensing arrangements, or of the nature of the input device, e.g. tap gestures based on pressure sensed by a digitiser
    • G06F3/0488Interaction techniques based on graphical user interfaces [GUI] using specific features provided by the input device, e.g. functions controlled by the rotation of a mouse with dual sensing arrangements, or of the nature of the input device, e.g. tap gestures based on pressure sensed by a digitiser using a touch-screen or digitiser, e.g. input of commands through traced gestures
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00Optical elements other than lenses
    • G02B5/02Diffusing elements; Afocal elements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/22Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
    • B29C43/222Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length characterised by the shape of the surface
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/022Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing characterised by the disposition or the configuration, e.g. dimensions, of the embossments or the shaping tools therefor
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/026Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing of layered or coated substantially flat surfaces
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/04Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
    • B29C59/046Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts for layered or coated substantially flat surfaces
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/02Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00Optical elements other than lenses
    • G02B5/04Prisms
    • G02B5/045Prism arrays
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00Optical elements other than lenses
    • G02B5/12Reflex reflectors
    • G02B5/136Reflex reflectors plural reflecting elements forming part of a unitary body
    • GPHYSICS
    • G02OPTICS
    • G02FOPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
    • G02F1/00Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
    • G02F1/01Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour 
    • G02F1/13Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour  based on liquid crystals, e.g. single liquid crystal display cells
    • G02F1/133Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333Constructional arrangements; Manufacturing methods
    • G02F1/1335Structural association of cells with optical devices, e.g. polarisers or reflectors
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0827Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using UV radiation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/022Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing characterised by the disposition or the configuration, e.g. dimensions, of the embossments or the shaping tools therefor
    • B29C2059/023Microembossing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0002Condition, form or state of moulded material or of the material to be shaped monomers or prepolymers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2011/00Optical elements, e.g. lenses, prisms
    • B29L2011/0083Reflectors
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2551/00Optical elements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/02Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
    • B32B37/025Transfer laminating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00Ancillary operations in connection with laminating processes
    • B32B38/06Embossing

Definitions

  • the present invention relates to an optical film, and in particular to an optical film having high viewability when adhered on an input/output device such as a touch panel or graphic panel.
  • the present invention also relates to a method of manufacturing such a high performance optical film easily with high accuracy.
  • the present invention also relates to an image display device comprising such an optical film provided on the image display surface thereof.
  • LCD liquid crystal displays
  • EL electroactive polymer
  • plasma displays and the like, and can be used for large- sized or small-sized image display devices.
  • Many applications utilize input/output devices such as a touch panels or graphic panels with electronic displays.
  • touch panels are widely used for ATMs (Automated Teller Machines) of banks, since recent liquid crystal display panels have been improved in visibility.
  • ATMs Automated Teller Machines
  • PDAs personal data assistants
  • PDAs include, for example, those sold under the trade names "Zaurus” of Sharp Corp., “Newton” of Apple Computer Inc., “Cassiopeia” of Casio Computer Co., Ltd., and "Visor” of Handspring.
  • a user can perform input operation easily by touching the touch panel with a stylus pen.
  • graphic panels are used to indicate equipment, instruments, and the like in industrial settings. An operator or user of a factory can monitor the equipment, instruments, and the like displayed on a graphic panel and control the factory by directly touching the display surface of the graphic panel with a his/her finger or a stylus pen.
  • the performance of a touch panel, graphic panel, or other input/output device heavily depends on the visibility of the liquid crystal display panel.
  • the visibility of the liquid crystal display panel is unable to be maintained with stability for the long term as a result of performing input/output operation by directly touching the image display surface (hereinafter called “touch input/output surface”, “touch input surface”, or “touch surface”) of the input/output device with a finger or pen.
  • touch input/output surfaces As a result of performing various operations repeatedly by touching the touch input/output surface with a user's finger or a pen, the transparency of the whole of the touch input/output surface is reduced due to the reflection of light on the touch input/output surface, and thereby the visibility of the touch input/output surface is reduced. Furthermore, when the reflection of light as described above exists, the periphery of the touch input/output surface may be reflected into the touch input/output surface, and thereby the visibility is reduced. Conventionally, in order to prevent the reduction of the visibility of the touch input/output surface, touch input/output surfaces have been provided with a pattern of bumps or dips.
  • a transparent film substrate manufacturing method has been proposed to manufacture a transparent film substrate provided on the touch side of a touch panel, and in which the touch input surface side of the substrate is roughened to a centerline average roughness of 0.05 to 0.8 ⁇ m, and the roughened surface is coated with transparent metallic compound or synthetic resin (Japanese Unexamined Patent Publication (Kokai) No.10-172377).
  • a molded object such as lens has been proposed which does not target the improvement of the visibility of a touch panel, but prevents eyestrain by reducing the reflection of light, and is excellent in the sense of wearing (Japanese Unexamined Patent Publication (Kokai) No.5-123378).
  • a transparent coating layer which includes a fine particle-like inorganic substance consisting of one or more kinds of particular metallic oxides, and a silicon high-molecular compound consisting of one or more kinds of particular organosilicon compounds.
  • One aspect of the present invention is an optical film comprising a transparent reflecting film on the surface of which a plurality of surface reflection distribution areas each containing at least one microstructure are provided.
  • the transparent reflecting film may be used alone, that is, without a substrate supporting it, or may be supported by a substrate.
  • the optical film preferably comprises a transparent sheet-like substrate and a transparent reflecting film (also called "reflecting layer" in this specification) formed on one side of the substrate.
  • Another aspect of the present invention is an optical film manufacturing method comprising a step of making a reflecting film by adding a plurality of surface reflection distribution areas each containing at least one microstructure to one side of a transparent film by transfer.
  • the reflecting film may be made in the form of a self-sustained film without a substrate, or in the form of a transparent reflecting layer supported by a transparent sheet-like substrate.
  • the transfer of the surface reflection distribution areas may be performed by using an embossing technique, or by charging curable or settable molding material in a mold and hardening the curable or settable molding material.
  • Another aspect of the present invention is an image display device comprising an optical film according to the present invention provided on the image display surface of the image display panel thereof.
  • Fig.1 is a plan view showing a preferred embodiment of an optical film according to the present invention.
  • Fig.2 is a cross-sectional view of the optical film shown in Fig.1 taken along line ⁇ - ⁇ .
  • Fig.3 is a cross-sectional view showing another preferred embodiment of an optical film according to the present invention.
  • Fig.4 is a cross-sectional view showing another preferred embodiment of an optical film according to the present invention.
  • Fig.5 is a cross-sectional view showing another preferred embodiment of an optical film according to the present invention.
  • Fig.6 is a partially enlarged view of the optical film shown in Fig.5.
  • Fig.7 is a perspective view of a PDA on which an optical film according to the present invention is adhered.
  • Fig.8 is a cross-sectional view of the PDA shown in Fig.7 taken along line Vffl- VIII.
  • Fig.9 is a cross-sectional view showing, in sequence, a preferred method of manufacturing an optical film according to the present invention.
  • FigJO is a schematic view showing another preferred method of manufacturing an optical film according to the present invention.
  • the stylus slides on the surface.
  • bumps and dips are formed at random on the touch surface as described above, the stylus movement can be adversely affected, resulting in poor performance and incorrect inputs.
  • the touch surface is scratched with a stylus.
  • the invention is aimed at solving the technical problems identified above. That is, it is an object of the present invention to provide an optical film which is improved in visibility, that resists fingerprinting that can deteriorate display contrast, and is capable of resisting scratches.
  • the present invention provides an optical film that can be adhered to an input/output device such as a touch panel or graphic panel, the optical film providing the input/output surface.
  • the present invention resides in an optical film, an optical film manufacturing method, and an image display device comprising an optical film according to the present invention adhered on the image display surface thereof. Preferred embodiments of the present invention are described below with reference to the accompanying drawings. However, the present invention is not limited to particular embodiments described below.
  • An optical film according to the present invention may be provided in the form of a self-sustained film or a film supported by a substrate.
  • Figs.1 and 2 show an example of an optical film supported by a substrate.
  • the optical film 10 comprises at least a transparent sheet-like substrate 1 and a transparent reflecting layer 2 formed on the substrate 1.
  • the optical film 10 includes a plurality of surface reflection distribution areas A on the surface of the reflecting layer 2, and in each of the areas, a microstructure 12 is formed (for example, a prismatic microstructure shaped like a quadrangular pyramid).
  • Two or more microstructures 12 may be formed in each of the surface reflection distribution areas A if required, which is not shown in the figures. It is preferable that the microstructures 12 on the reflecting layer 2 are disposed in a regular pattern, have a predetermined shape and height, and are distributed with a predetermined density.
  • surface reflection distribution areas are provided on the reflecting layer formed on the transparent sheet-like substrate by disposing the transparent microstructures (preferably prismatic microstructures) which are controlled in shape, height, and distribution density, and thereby light incident on the surface of the optical film can be reflected in various directions by the surfaces of the microstructures, and strong mirror reflection to a particular direction from the plane surface can be prevented.
  • microstructure means a surface pattern which is very minute, and the existence of which is unable to be substantially detected with the naked eye. That is, the microstructure is a microscopic minute structure incapable of being clearly distinguished when it is observed visually from any of the surfaces of it.
  • the term "microscopic” refers to features of small enough dimension so as to require an optic aid to the naked eye when viewed from any plane of view to determine its shape.
  • the transparent sheet-like substrate may be made of various materials in different thicknesses.
  • the sheet-like substrate preferably at least has thickness that does not affect the visibility, durability, etc., and flexibility enough to the adhering work, in consideration of being used for an image display device being adhered on the image display surface of it.
  • this optical film is intended to be used for an input/output device such as a touch panel being adhered on it, it is required to have hardness and durability enough to withstand the pressure applied by a finger or pen, and flexibility enough to transfer the pressure precisely to the input/output device.
  • Preferred sheet-like substrates in the practice of the present invention include but are not limited to plastic films made of polyethylene terephthalate (PET), polyethylene naphtalate (PEN), oriented polypropylene, polycarbonate, triacetate, or the like.
  • PET film is useful as a substrate.
  • a polyester film such as a TetronTM film, MELL EXTM film (available from DuPont Teijin), or the like may be used as a substrate.
  • plastic films are normally used as a single layer film, but two or more kinds of these films may be combined, if required, to be used as a composite film or laminated film.
  • a sheet-like substrate may be used in various thickness according to the layer construction, the particular application, or the like of an optical film, and is generally used in the thickness of about 10 ⁇ m to about 500 ⁇ m, and preferably about 50 ⁇ m to about 300 ⁇ m.
  • the microstructures of its reflecting layer may be made in various forms within the scope of the objects and effect of the present invention, and are preferably prismatic microstructures, because the prismatic microstructures are able to disperse light in a plurality of directions to prevent glare.
  • Non- limiting examples of a prismatic microstructures includes those shaped like a quadrangular pyramid as shown in Figs. 1 and 2, a triangular pyramid, a truncated pyramid, or the like.
  • Fig. 3 shows an example of an optical film 10, wherein a reflecting layer 2 is formed on a sheet-like substrate 1, and one prismatic microstructure shaped like a quadrangular truncated pyramid is formed in each of the surface reflection distribution areas A of the reflecting layer 2.
  • the microstructures may be integrated, if desired, with the underlain sheet-like substrate by omitting the reflecting layer 2, or a reflecting layer may be constructed as a reflecting film by omitting a sheet-like substrate, which results an optical film without a substrate (self-sustained optical film).
  • the microstructures may be formed in various sizes.
  • the length of one side of the rectangle is normally about 10 ⁇ m to about 500 ⁇ m, and preferably about 50 ⁇ m to about 300 ⁇ m.
  • the height of a microstructure is normally about 10 ⁇ m to about 500 ⁇ m, and preferably about 50 ⁇ m to about 300 ⁇ m, although it is slightly variable according to whether the microstructure is truncated or not.
  • the material of the reflecting layer on which microstructures such as prismatic microstructures are provided is not limited, subject to the preference for visible light transparency. Glass, various plastic materials, or the like can be used to form the reflecting layer, and plastic materials are used advantageously from the viewpoint of workability.
  • the reflecting layer may be made of various plastic materials and in different thicknesses according to the layer construction of the optical film, its intended use, or the like.
  • Suitable plastic materials include but are not limited to acrylic resin, polycarbonate resin, polyester resin, urethane resin, epoxy resin, polystyrene resin, and the like, and mixtures of these resins.
  • An exemplary plastic material may be selected as appropriate in consideration of optical characteristics such as viscosity (effective on handleability), refractive index, and the like of these resins.
  • a PET or the like is suitable as a reflecting layer material. When the microstructures are very fine and not easily formed, it is recommended that the microstructures are formed by a transcription method or the like as described below.
  • the reflecting layer is preferably formed from a hardened article of curable or settable resin material. That is, the reflecting layer may be a film made in a manner that the curable or settable resin material is formed like a film and then hardened by applying heat, light, or other energy to it.
  • the curable or settable resin material is thus preferably a heat-curable resin material or a photo-curable resin material, or a thermoplastic resin material.
  • photo-curable (e.g., UV-curable) resin materials do not require a long and large furnace for forming a reflecting layer and are able to be cured in a relatively short time, thus being useful.
  • Photo-curable resin materials preferably include photo-curable monomers and oligomers, and further preferably include (meta) acrylate monomers and oligomers, that is, acrylate or methacrylate monomers and oligomers.
  • acrylate monomers suitable for forming the reflecting layer include but are not limited to urethanacrylate, polyesteracrylate, polyetheracrylate, acrylamide, acrylonitrile, acrylic acid, acrylic acid ester, etc.
  • Acrylate oligomers suitable for forming the reflecting layer include but are not limited to urethanacrylate oligomers, epoxyacrylate oligomers, etc.
  • urethanacrylate and its oligomers can be cured to be flexible and stiff articles at extremely higher speed than that of all other acrylate, thereby contributing to the improvement of productivity of optical films.
  • an optically transparent reflecting layer can be obtained.
  • These acrylate monomers and oligomers may be used alone or in optional combinations of two or more kinds of them. Particularly described above are features, etc. of acrylate monomers and oligomers, although methacrylate monomers and oligomers also have similar features, etc.
  • Curable or settable resin materials may contain optional additives. For example, in cases where the curable resin materials are photo-curable resin materials, photo- polymerization initiators are suitable additives for them.
  • compounds can be selected as suitable photo-polymerization initiators in accordance with the kinds of curable resin materials.
  • exemplary compounds include phenoxyethyl acrylate, 2-hydroxy-2- methyl- 1 -phenyl-propane- 1 -on, bis(2,4,6-trimethylbenzoyl)-phenylphosphine-oxide, etc. These photo-polymerization initiators may be used alone or in combination of two or more kinds of them.
  • the reflecting layer may be used in various thicknesses on the sheet-like substrate according to the layer construction of the optical film, its intended use, or the like. The thickness of the reflecting layer is normally about 5 ⁇ m to about 1000 ⁇ m, and preferably about 10 ⁇ m to about 100 ⁇ m.
  • the optical film may further comprise optional elements in addition to the sheetlike substrate and reflecting layer.
  • Fig. 4 is a cross-sectional view of another optical film according to the present invention obtained by providing an additional layer on the optical film described before with reference to Fig. 2.
  • the optical film 10 shown in Fig. 4 further comprises a transparent thin protective coating 3 formed on the reflecting layer 2 formed on one side of the sheet-like substrate 1.
  • the protective coating 3 may be formed as a hard coat layer if desired.
  • a release liner 5 is adhered through an adhesive layer 4.
  • the optical film 10 can be easily adhered to a touch panel or the like by peeling off the release liner 5.
  • the protective coating When the protective coating is formed as the top layer of the optical film in the form of a thin coating, it gives to the optical film a stain resistance, good durability, and good strength.
  • the protective coating may be made of various materials by an optional coating making method, and preferably made of a low adhesion compound from the viewpoint of preventing the adhesion of dust or the like.
  • Low adhesion compounds suitable for making the protective coating include but are not limited to fluorine- containing compounds, silicon-containing compounds, etc.
  • fluorine- containing compounds are suitable, because they are excellent in transparency and adherence to the underlying reflecting layer and can be formed in thin coating without damaging the microstructures on the surface of the reflecting layer.
  • Fluorine-containing compounds suitable for making the protective coating include compounds containing a perfluoro polyether group and an alkoxy silane group in the molecules.
  • This coupling agent is commercially available under the trade name "Optool DSX" from Daikin.
  • the protective coating may be formed in various thicknesses, and is preferably as thin as possible in consideration of the reappear of the microstructures, etc.
  • the thickness of the protective coating is normally about 0J to about 200 nm, preferably about 0.5 to about 100 nm.
  • the adhesive layer 4 is preferably covered with a release liner in consideration of its handleability, etc.
  • regular ones may be respectively used in optional thickness.
  • the release liner may be constructed advantageously from various base materials.
  • Base materials suitable for making the release liner include paper, plastic materials such as polyethylene, polypropylene, polyester, cellulose acetate, polyvinyl chloride, and polyvinylidene fluoride, and paper and other materials covered with such a plastic material or on which such a plastic material is adhered.
  • the release liner may be used as it is, and preferably used after it is treated by a silicone treatment method or other method to improve the peel characteristic of it.
  • the thickness of the release liner is normally but not limited to about 25 ⁇ m to about 200 ⁇ m.
  • the adhesive layer may be made of various adhesives such as pressure-sensitive adhesives (PSA).
  • Pressure-sensitive adhesives useful for making the adhesive layer include but are not limited to acrylic adhesives, tackifier rubber, tackifier synthetic rubber, ethylene-vinyl acetate, silicone, etc.
  • Such an adhesive may be a polymer coated on the release liner after being dispersed into solvent or water and then dried, or further cross-linked optionally.
  • a solvent or water bone pressure-sensitive adhesive composition is used, a drying process for removing all or much of solvent or water is required for making the adhesive layer.
  • the adhesive may be a hot-melt adhesive.
  • an adhesive composition having low molecular weight may be coated on the release liner and then polymerized by the radiation of energy such as heat, UV, or electron beam.
  • the thickness of the adhesive layer may be changed in wide range in accordance with many factors including, for example, the composition of the adhesive, the construction of the optical film, and the thickness of the release liner. In general, the thickness of the adhesive layer is about 10 ⁇ m to about 50 ⁇ m.
  • Fig. 5 shows an example of a self-sustained optical film without a substrate as a support.
  • the optical film 41 is one modification of the above-described optical film comprising a support having applied thereon a reflecting layer, and has many microstructures 42 (fine prismatic microstructures shaped like a quadrangular truncated pyramid) on the surface thereof as shown in Fig. 6, which is enlarged view of it.
  • the optical film 41 may be made of plastic material, in optional thickness, similar to that of the aforementioned sheet-like substrate and reflecting layer.
  • the thickness of the optical film 41 is normally about 10 ⁇ m to about 1000 ⁇ m.
  • the pitch (p) of the microstructures 42 is normally variable between about 160 ⁇ m and about 254 ⁇ m, and the height of them is normally variable between about 10 ⁇ m to 15 ⁇ m.
  • the optical film 41 shown in Fig.5 has an adhesive layer 44 and release liner 45 on a back surface thereof.
  • the adhesive layer 44 and release liner 45 may be respectively made of the same materials in the same thickness as ones of the adhesive layer 4 and release liner 5 of the optical film 10 described with reference to Fig. 4.
  • the optical film 41 may include an optically transparent PET film having the thickness of 50 ⁇ m and is provided with the adhesive layer 44 having the thickness of 25 ⁇ m made of an acrylic adhesive and a polyester (PET) release liner 45 having the thickness of 35.5 ⁇ m covered with a silicon release agent (not shown).
  • the PET film is a MELINEXTM film.
  • the optical film 41 is profiled with a plurality of quadrangular truncated pyramid microstructures 42 formed, as described above, in a pattern with a pitch variable between 160 and 254 ⁇ m and a depth variable between 10 and 15 ⁇ m.
  • the microstructure 42 may be formed easily in a manner that a PET film is disposed on a heated steel roll (mold) and embossed by using a flame embossing technique.
  • the height of the quadrangular truncated pyramid microstructures would decrease with increasing the density of them (with decreasing the pitch of them).
  • Optical characteristics measured on the optical film 41 were the transmittance, haze value, and transparency.
  • the haze value of the optical film increased with increasing the density of the pattern, but no substantial change was noted for the transmittance and transparency.
  • the optical film according to the present invention may be used for various image display devices normally being adhered on the image display surface of each of the image display devices in a manner that the reflecting layer side of the optical film is exposed.
  • Suitable image display devices include but are not limited to LCD devices, EL display devices, plasma display devices, etc.
  • the optical film may be adhered to an article or device other than image display devices.
  • the optical film may be suitably used as, for example, displaying means including graphics films, photograph plates, signboards, etc.
  • the optical film of the present invention may be, in particular, advantageously used in combination with an image display device having an input/output device such as a touch panel or graphic panel in a manner that it is adhered on the touch surface of the input/output device, because even if an input operation is performed by touching the reflecting layer of the optical film with a pen or finger, various characteristics peculiar to the optical film are not deteriorated and the damage, contamination, etc. of the optical film can be substantially reduced or avoided.
  • Image display devices equipped with an input/output device include but are not limited to touch panel-type car navigation systems, automated teller machines (ATMs) of banks, and personal data assistants (PDAs), etc. Accordingly, the present invention also resides in an image display device comprising the aforementioned optical film provided on the image display surface of its image display panel. Furthermore, an image display device according to the present invention may be advantageously realized in various forms, and preferably has an input/output device such as a touch panel on its image display panel and has an optical film according to the present invention on the input/output device.
  • Fig. 7 is a perspective view of a PDA that includes a typical image display device according to the present invention. The construction of it can be understood from Fig. 8, which is a cross-sectional view taken along line VIII- VLU of Fig. 7.
  • the PDA 30 is so constructed that a liquid crystal display device 35 is accommodated in a casing 36, a touch panel 31 is disposed on the image display surface of the liquid crystal device 35, and an optical film 41 according to the present invention is adhered on the touch panel 31. Note that Fig.
  • the optical film 41 has the structure as explained with reference to Figs. 5 and 6.
  • the optical film 41 includes a MELINEXTM film, which is an optically transparent polyester (PET) film, having the thickness of 50 ⁇ m, on the surface of which microstructures (quadrangular truncated pyramid microstructures) (not shown) are formed. Further, on a back surface of the optical film 41 used herein, a PET release liner having the thickness of 35.5 ⁇ m has been adhered through an acrylic adhesive layer having the thickness of 25 ⁇ m, as described with reference to Fig. 5, before the optical film 41 is adhered on the touch panel 31.
  • PET optically transparent polyester
  • the thickness of the optical film 41 and others should not be restricted to the above example.
  • the thickness of the optical film is in the range of about 10 to 100 ⁇ m
  • the thickness of the acrylic adhesive layer is in the thickness of about 5 to 50 ⁇ m
  • the thickness of the PET release liner is in the range of about 20 to 200 ⁇ m.
  • the optical film 41 can be easily adhered on the touch panel 31.
  • troubles such as air entrainment (capture of bubbles) do not occur.
  • An acrylic adhesive to be used has adhesive power of a controlled level so that the optical film does not peel off spontaneously, and may be removed without leaving behind any substantial paste material when the optical film is renewed. Furthermore, a thin hard coat layer may be applied on the optical film so that resistance to scratching is increased for a certain period.
  • the optical film 41 may temporarily protect the image display portion of the PDA.
  • the optical film 41 is capable of protecting the screen of the PDA from dust and dirt in air in addition to scratching, and when an input operation to the touch panel is performed with a stylus pen 37, the pen does not slide on the touch panel, and the input operation can be continued easily with stability and excellent quality of writing. That is, the optical film according to the present invention has surface roughness to a certain extent because of the microstructures on the surface of it, thereby having a tactile property much like paper.
  • the microreplicated pattern used is desirably tailored such that the transmission, haze and clarity of the protective film and display are not substantially compromised, and the sensitivity of the sensors detecting the stylus pen writing on the screen is not substantially reduced.
  • the optical film 41 has microstructures formed in a regular pattern on its surface, the reflection of light can be effectively controlled by optimizing the pattern in dimension and distribution density, and thereby the glare of the screen or the like can be reduced.
  • An optical film according to the present invention may be advantageously manufactured by various methods.
  • a particularly advantageous manufacturing method is a transfer method.
  • the transfer method may be implemented in various manners.
  • a long size optical film may be continuously made and cut into individual optical films at a downstream process, or optical films may be made one by one or in a few batches.
  • the transfer method may be implemented by using an embossing technique, or in a manner that curable or settable molding material is charged in a mold and then hardened.
  • the mold includes a metallic mold, sheet-like mold, or the like.
  • a preferred embodiment of the present invention is a method of manufacturing an optical film comprising a transparent sheet-like substrate and a transparent reflecting layer formed on one side of the substrate, which includes, after forming the sheet-like substrate, the step of forming a reflecting layer, on one side of the substrate by transfer, having a plurality of surface reflection distribution areas each containing at least one microstructure.
  • a method of manufacturing an optical film according to the present invention in a transfer manner may be implemented preferably according to the following steps.
  • Mold making step Making a mold comprising a support and a shaping layer (hereinafter also referred to "form adding layer") which is provided on the support and has a pattern of microstructure duplicating grooves , on the surface thereof, having a form, height, and distribution density corresponding to the micro structures of the surface reflection distribution areas.
  • Molding material charging step Disposing curable or settable molding material between the sheet-like substrate and the shaping layer and charging the molding material in the microstructure duplicating grooves.
  • Optical film making step Hardening the molding material to form an optical film comprising the sheet-like substrate and a reflecting layer on the surface of which microstructures integrally coupled with the sheet-like substrate are provided.
  • Optical film removing step Removing the optical film from the mold.
  • the sheet-like substrate may be continuously supplied from a roll of substrate or may be supplied one by one.
  • the optical film may be made by a batch system, or in a manner that a large optical seat consisting of many optical films is made and then cut into individual optical films. More specifically, the optical film manufacturing method described above may be advantageously implemented step by step as shown in Fig. 9.
  • a mold 20 as shown in Fig. 9(A) is prepared.
  • the mold 20 comprises a support 21 and a shaping layer 22 which is provided on the support 21 and has a pattern of microstructure duplicating grooves 25, on the surface thereof, having a form, height, and distribution density corresponding to the micro structures of the surface reflection distribution areas.
  • the mold 20 may be made, for example, according to the steps of: adhering an photo-curable resin material to a metallic mold (a replica of a target optical film), which has a pattern of protrusions having a form and dimensions corresponding to the pattern of grooves of the mold 20, to form an photo-curable resin material layer; attaching a transparent support consisting of a plastic film onto the metallic mold to form a laminated article consisting of the metallic mold, the photo-curable resin material layer, and the support; applying light to the laminated article from the support side of it to cure the photo- curable resin material layer; and removing the shaping layer formed by curing the photo-curable resin material layer, together with the support from the metallic mold.
  • a transparent sheet-like substrate 1 is set on a platen (not shown) and then the flexible mold 20 is disposed in a predetermined position on the substrate 1, and alignment between the substrate 1 and mold 20 is performed.
  • a laminating roll 23 is placed on one end portion of the mold 20.
  • the laminating roll 23 is preferably a rubber roll.
  • the end portion of the mold 20 is preferably fixed on the substrate 1, because the displacement between the substrate 1 and mold 20 on which alignment has been completed can be prevented.
  • the free end portion of the mold 20 is moved upward to the laminating roll 23 while being lifted with a holder (not shown) to expose the substrate 1.
  • plastic material photo-curable resin
  • a paste hopper with a nozzle for example, may be used.
  • the plastic material 12 is not supplied evenly onto the whole of the substrate 1.
  • the plastic material 12 may be supplied only to the portion, as shown in Fig. 9(A), near the laminating roll 23, on the substrate 1, because the plastic material 12 can be spread evenly on the substrate 1 when the laminating roll 23 moves on the mold 10 at a step described later.
  • the viscosity of the plastic material is preferably adjusted so as to be suitable for such spreading.
  • the viscosity of the plastic material is normally about 20,000 cps or less.
  • a method for supplying the plastic material is not limited to the methods described.
  • the plastic material may be coated on the whole surface of the substrate, which is not shown.
  • the rotating motor (not shown) is driven to move the laminating roll 23 on the mold 20, as indicated by an arrow in Fig. 9(A), at a predetermined speed.
  • the laminating roll 23 While the laminating roll 23 is being moved like this, pressure is applied to the mold by the weight of the laminating roll 23 in succession from one end of it to the other end, the plastic material is spread between the substrate 1 and the mold 20, and the plastic material 12 is charged in the grooves 25 of the mold 20. Furthermore, in the manufacturing method shown, the grooves of the mold serve as channels for air so that air captured in the grooves is discharged to the outside or around of the mold effectively by the above applied pressure. As a result, in this manufacturing method, even if the plastic material is charged in the grooves under atmospheric pressure, bubbles remaining in the grooves can be prevented. Next, the plastic material is hardened.
  • the laminated article consisting of the substrate 1 and the mold 10 is put into a photo-irradiation device (not shown), and then light such as ultraviolet light (UV) is applied to the plastic material 12 through the substrate 1 and the mold 20 to cure it.
  • UV ultraviolet light
  • the microstructures 12 made of photo-curable resin are obtained.
  • the substrate 1 and the mold 20 are taken out of the photo-irradiation device, and then the mold 20 is peeled off as shown in Fig. 9(C).
  • optical film 10 is shown, for the sake of simplicity, in a state that the microstructures 12 are integrally adhered to the sheet-like substrate 1, although the optical film 10 comprises, as a matter of fact, a reflecting layer made of material identical to that of the microstructures 12.
  • optical films 10 are made by a batch system, although they can be continuously made of a sheet-like substrate 1 supplied from a roll or by other method.
  • Optical films having microstructures on the surface of them may be advantageously formed also by using a flame embossing technique.
  • the flame embossing technique is known as a microreplication technique in which a sheet-like substrate consisting of, for example, a PET film is contacted to a heating roll having a pattern of grooves corresponding to the microstructures to soften the sheet-like substrate and emboss a pattern of the microstructures on the surface of it, by which an optical film is completed.
  • Fig. 10 schematically shows a method of continuously making optical films 41 shown in Fig. 6 by using a flame embossing technique.
  • the optical films 41 may be made in a manner that a sheet-like substrate film sent from a roll 40 of sheet-like substrate (e.g., PET film) is guided between a heated embossing roller 51 and a pressing rubber roller 53 at a predetermined speed.
  • the embossing roller 51 is made of steel and has a pattern of grooves 52 corresponding to a pattern of microstructures 42 to be added on the surface of an optical film 41.
  • the PET film passes through between a pair of rollers, it is softened, and the pattern of microstructures 42 is transferred to the surface of it. Examples
  • the present invention is described below with reference to its examples. It should be noted that the present invention is not limited to these examples.
  • Example 1 In this example, an optical film as described with reference to FigsJ and 2 was made. 100 wt.pts. of aliphatic urethan acrylate oligomer (trade name "Ebecryl270" of Daicel UBC Co., Ltd), 25 wt.pts. of phenoxy ethyl acrylate (trade name "Light Acrylate PO-A of Kyoeisha Chemical Co., Ltd.), and 1.25 wt.pts. of 2-hydroxy-2-methyl-l-phenyl- propane-1-on (photo-polymerization initiator, trade name "Darocurel l73" of Ciba Specialty Chemicals) were mixed to prepare microstructure forming UV-curable resin.
  • aliphatic urethan acrylate oligomer trade name "Ebecryl270" of Daicel UBC Co., Ltd
  • 25 wt.pts. of phenoxy ethyl acrylate trade name "Light Acrylate
  • a sheet-like mold made of polypropylene resin was prepared, the surface of which was engraved with a pattern of grooves corresponding to target prismatic microstructures.
  • necessary amount of UV-curable resin made at the previous step was coated on the prepared mold and charged in the grooves.
  • the mold was overlaid with a polyester (PET) film for a substrate.
  • PET film used at this step was PET film (trade name "HPE188" of Teijin) having the thickness of 100 ⁇ m.
  • UV-curable resin was charged in the concavities of the mold, light with the wavelength of 300 to 400 nm was applied to the UV-curable resin for 30 seconds through the PET film by using a fluorescent lamp of Mitsubishi Electric Osram Ltd.
  • the UV-curable resin was cured and a reflecting layer was obtained.
  • the PET film was peeled off together with the reflecting layer from the mold, and a target optical film as shown in Figs. 1 and 2 was obtained.
  • the thickness of the reflecting layer was about 300 ⁇ m.
  • the prismatic microstructures (quadrangular pyramid microstructures) formed on the surface of the reflecting layer had the pitch (p) of 110 ⁇ m, and the height of 63 ⁇ m.
  • Example 2 the reflecting layer of the optical film of Example 1 was laminated with a protective coating.
  • a fluorine silane coupling agent (trade name "Optool DSX"; Daikin) containing perfluoropolyether groups and alkoxy silane groups as given by the following formula was prepared as material of a protective coating.
  • F-(CF2CF 2 CF 2 O) n -Si(OMe)3 80 mol%
  • F-(CF 2 CF 2 CF 2 O) n -CF 2 CF 3 20 mol%
  • Me methyl group 20 wt.pts. of silane coupling agent was diluted with 80 wt.pts. of hydrofluoro ether
  • Example 1 (trade name "HFE-7100" of 3M), which was a fluorine agent, to prepare coating solution.
  • the optical film of Example 1 was steeped in the obtained coating solution to form a protecting coating made of a silane coupling agent on the reflecting layer side of the optical film.
  • the thickness of the protective coating was about 0J ⁇ m, and the prismatic microstructures on the reflecting layer were totally covered with the protecting coating.
  • Example 3 Evaluation Test
  • characteristics of the optical film of Example 2 were evaluated in terms of (1) visibility, (2) degree of reflection, and (3) degree of easiness of wiping off a fingerprint.
  • a commercially available matted polyester (PET) film 125 ⁇ m thickness, trade name "TetronTM” of Teijin
  • PET matted polyester
  • (1) Visibility Test After an optical film (inventive film) and a PET film (reference film) had been adhered on the image display surface of a commercially available PDA, the respective surfaces of the films were rubbed repeatedly with a finger so that fingerprint (sebum) stains were put on the surfaces. Next, the PDA was powered on, and then the visibility during image display was evaluated qualitatively.
  • the PDA was placed directly below the fluorescent light in the room at the distance of about 2 m from the light, and the degree of reflection of the fluorescent light into the optical film was observed with the naked eye from a slanting direction.
  • the inventive film light incident on the surface of the optical film was reflected in various directions by the surfaces of the prismatic microstructures, and thereby reflection of the fluorescent light into the inventive film could be prevented. That is, in case of the inventive film, the existence of the prismatic microstructures could prevent reductions in visibility due to the reflection of objects around the film into it.
  • the reflection of the fluorescent light into the film was distinctly observed.
  • the respective surface energies of the sample films were measured in terms of contact angles.
  • the contact angles (degree) were measured with a contact angle meter (trade name "CONTACT ANGLE METER” of Kyowa Kaimen Kagaku) using water of 0.05 ⁇ l based on a method required by JIS-R-3257. The following result of the measurement was obtained.
  • the present invention provides an optical film improved in visibility without the adhesion of a fingerprint and the deterioration of the contrast.
  • This optical film is capable of resisting a scratch or the like and preventing the adhesive of dust or the like, and even if dust or the like has adhered to this optical film, the dust or the like can be removed easily.
  • an optical film according to the present invention has such characteristics, it may be advantageously used for various image display devices, and in particular may be more advantageously used for input/output devices such as touch panels and graphic panels, being adhered on them. Furthermore, the present invention provides a method of manufacturing an optical film according to the present invention easily with high accuracy. Furthermore, the present invention provides an image display device taking advantages of the excellent characteristics of an optical film according to the present invention.

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  • General Physics & Mathematics (AREA)
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  • Optics & Photonics (AREA)
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Abstract

La présente invention se rapporte à un film optique (10) dont la visibilité est améliorée et qui ne présente ni adhérence d'une empreinte digitale ni détérioration du contraste, ledit film étant capable de résister aux rayures et analogues et s'avérant particulièrement utile pour un panneau tactile de dispositif d'affichage d'images. Ce film optique (10) comprend un film de réflexion transparent (2) à la surface duquel sont présentes une pluralité de zones de répartition de la réflexion en surface (A), chacune de ces zones contenant au moins une microstructure.
PCT/US2004/012267 2003-06-06 2004-04-20 Film optique microstructure et procede de production associe WO2005003822A1 (fr)

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AU2004254901A AU2004254901A1 (en) 2003-06-06 2004-04-20 Microstructured optical film and production process thereof
US10/559,521 US20060132945A1 (en) 2003-06-06 2004-04-20 Microstructured optical film and production process thereof
EP04750422A EP1631847A1 (fr) 2003-06-06 2004-04-20 Film optique microstructure et procede de production associe

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JP2003162477A JP2004361835A (ja) 2003-06-06 2003-06-06 光学フィルム及びその製造方法

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KR20060014436A (ko) 2006-02-15
TW200521472A (en) 2005-07-01

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