WO2010095402A1 - Method and apparatus for manufacturing optical member having surface shape - Google Patents

Method and apparatus for manufacturing optical member having surface shape Download PDF

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Publication number
WO2010095402A1
WO2010095402A1 PCT/JP2010/000880 JP2010000880W WO2010095402A1 WO 2010095402 A1 WO2010095402 A1 WO 2010095402A1 JP 2010000880 W JP2010000880 W JP 2010000880W WO 2010095402 A1 WO2010095402 A1 WO 2010095402A1
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surface shape
substrate
optical member
cooling
heating
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PCT/JP2010/000880
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French (fr)
Japanese (ja)
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後藤修一
南波芳典
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出光ユニテック株式会社
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Priority to JP2011500495A priority Critical patent/JPWO2010095402A1/en
Publication of WO2010095402A1 publication Critical patent/WO2010095402A1/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing

Definitions

  • the present invention relates to a method for manufacturing a surface-shaped optical member and a device for manufacturing a surface-shaped optical member.
  • Light guide plates For taking light from the light source (for example, fluorescent tube or LED) of the backlight unit from the side, from small liquid crystal displays such as cellular phones to large liquid crystal displays such as personal computers and televisions, and for introducing (light emission) on the screen Light guide plates are widely used.
  • the light source for example, fluorescent tube or LED
  • small liquid crystal displays such as cellular phones
  • large liquid crystal displays such as personal computers and televisions
  • light guide plates are widely used.
  • the light guide plate is provided with a surface shape called an optical pattern, and transmitted light from the side surface of the screen is reflected by the surface shape and can be emitted on the screen (Patent Documents 1 and 2). Along with the thinning of the liquid crystal display on the market, the light guide plate was also required to be thin.
  • An optical member with a surface shape such as a light guide plate is manufactured by transferring the surface shape to an optical member substrate (for example, a polycarbonate light guide plate, a diffusion plate, etc.).
  • an optical member substrate for example, a polycarbonate light guide plate, a diffusion plate, etc.
  • a method for transferring the surface shape to the optical member for example, an injection molding method, a method using a vacuum apparatus, and the like have been studied (Patent Documents 3 to 9).
  • the light guide plate is required to be thin.
  • the surface shape of the optical member with a surface shape cannot be efficiently and accurately molded by injection molding. There was a problem. Specifically, for example, bubbles remain between the mold and the substrate, and because the resin does not flow into the mold end, the variation in the transfer rate increases and the yield deteriorates. Driving was difficult.
  • the surface shape imparting mold for transferring the surface shape to the substrate is thick, and when performing all of vacuum, thermoforming and cooling, the heating / cooling efficiency is poor and the time Therefore, there is a problem that the manufacturing efficiency is poor.
  • An object of this invention is to provide the manufacturing method of the optical member with a surface shape which can perform the surface shape shaping
  • An object of this invention is to provide the manufacturing apparatus of the optical member with a surface shape which can perform the surface shape shaping
  • the following method for producing a surface-shaped optical member is provided.
  • the method for producing an optical member with a surface shape according to 1 or 2 wherein a sandwiching surface of the flexible sheet is cooled to 5 to 100 ° C. 4).
  • Substrate clamping means having a surface shape imparting mold on at least one of the clamping surfaces for clamping the substrate; Heating / pressurizing means for heating / pressurizing the substrate to form a surface shape pattern on at least one surface of the substrate;
  • substrate for optical members efficiently and accurately can be provided.
  • ADVANTAGE OF THE INVENTION According to this invention, the manufacturing apparatus of the optical member with a surface shape which can perform the surface shape shaping
  • the method of manufacturing an optical member with a surface shape includes a step of sandwiching a substrate with a pair of flexible sheets having a surface-shape imparting mold on at least one of the sandwiching surfaces, a vacuum between the pair of flexible sheets, and a pair of flexible sheets Forming a surface shape pattern on at least one surface of the substrate by heating and pressing the sandwiching surface of the substrate, and cooling the sandwiching surfaces of the pair of flexible sheets to solidify the substrate on which the surface shape pattern is formed.
  • the surface shape is transferred (surface shape molding) in a state in which the air interposed between the substrate and the surface shape imparting mold is removed. Can be suppressed. Further, since the flexible sheet having the surface shape imparting mold is used, the adhesion of the surface shape imparting mold to the substrate can be improved, and the transfer accuracy to the substrate can be improved. Furthermore, since the optical member with a surface shape can be continuously formed in the present invention, the optical member with a surface shape can be efficiently manufactured as compared with batch-type molding.
  • Examples of the material of the substrate used for manufacturing the optical member with a surface shape include polycarbonate (PC), polyethylene terephthalate (PET), cyclic polyolefin, acrylic, polystyrene (PS), and the like.
  • the thickness of the substrate is usually 0.05 to 6.0 mm, preferably 0.1 to 3.0 mm.
  • the flexible sheet is preferably a sheet of metal (for example, aluminum, copper, brass, etc.) having high thermal conductivity.
  • the thickness of the flexible sheet is preferably 0.5 to 3 mm.
  • the pair of flexible sheets has a surface shape imparting mold on at least one of the sandwiching surfaces.
  • the optical member is a diffuser plate
  • the surface shape pattern formed by the surface shape imparting mold improves the brightness by condensing and / or diffusing incident light from the light source by transferring the pattern onto the substrate surface.
  • it is a shape which can reduce a brightness nonuniformity, it will not specifically limit.
  • the optical member is a light guide plate, there is no particular limitation as long as it is a shape that can improve luminance and reduce luminance unevenness by reflecting and emitting incident light from the light source by transferring the pattern onto the substrate surface.
  • the optical member is not limited to the diffusion plate and the light guide plate.
  • Examples of the surface shape pattern include shapes such as a prism, a Fresnel lens, a lenticular lens, and a hemispherical dot having shapes such as a linear shape, a triangular pyramid, and a quadrangular pyramid.
  • a vacuum is applied between the pair of flexible sheets.
  • the degree of vacuum is usually ⁇ 30 to ⁇ 100 kPa, preferably ⁇ 50 to ⁇ 100 kPa.
  • the flexible sheet After evacuating between the pair of flexible sheets, the flexible sheet is heated and pressurized to form a surface shape pattern on at least one surface of the substrate.
  • the heating temperature is usually 90 to 260 ° C.
  • the heating temperature is preferably 160 to 230 ° C.
  • the pressurizing pressure is usually 0.5 to 50 kgf / cm 2 .
  • the pressurizing pressure is preferably 10 to 40 kgf / cm 2 .
  • the heating / pressurizing time is usually 1 to 60 seconds, preferably 5 to 15 seconds.
  • the pair of flexible sheets are cooled, the substrate on which the surface shape pattern is formed is solidified, and the substrate with surface shape (optical member with surface shape) is peeled from the flexible sheet.
  • the cooling temperature is usually 5 to 100 ° C., preferably 10 to 30 ° C.
  • the cooling treatment time is usually 1 to 60 seconds, preferably 3 to 15 seconds.
  • the heating temperature, pressurizing pressure, heating / pressurizing treatment time, cooling temperature, and cooling treatment time have been described above, but are not limited to the above, and can be appropriately selected depending on the softening temperature and melting temperature of the resin used as the substrate. .
  • FIG. 1 is a schematic top view of an embodiment of an optical member manufacturing apparatus with a surface shape according to the present invention.
  • FIG. 2 is a schematic side view of an embodiment of an optical member manufacturing apparatus with a surface shape according to the present invention.
  • FIG. 3 is a schematic front view of an embodiment of the optical member manufacturing apparatus with a surface shape according to the present invention.
  • the surface-shaped optical member manufacturing apparatus 1 shown in FIGS. 1 to 3 is a rotary vacuum transfer apparatus, and includes a sheet supply slide unit 20 that supplies a substrate 10 and a flexible sheet (substrate clamping means) that clamps the substrate 10.
  • 50 cooling means
  • a sheet take-out slide unit 60 for taking out the substrate whose surface shape has been transferred are provided on the same plane.
  • the sheet supply slide unit 20, the heating / pressurizing mechanism 40, the cooling / pressurizing mechanism 50, and the sheet take-out slide unit 60 are arranged in this order on a concentric circle around the rotation axis of the chamber 30 that rotates intermittently.
  • the substrate 10 is supplied from the sheet supply slide unit 20 and filled in the chamber 30.
  • the chamber 30 filled with the substrate 10 is rotated about the rotation axis by using a servo motor or the like as a drive source and is rotated to the heating and pressurizing mechanism 40.
  • the chamber 30 is closed during rotation to the heating and pressurizing mechanism 40, and evacuation is started by a vacuum valve, and the inside of the chamber 30 is evacuated.
  • FIG. 4 is a schematic cross-sectional view of the chamber 30 filled with the substrate 10 moved to the heating and pressurizing mechanism 40.
  • the substrate 10 is sandwiched between a pair of flexible sheets 34 (substrate sandwiching means) with the surface shape imparting mold 32 as a sandwiching surface.
  • a vacuum area 38 is formed in the chamber 30 by an O-ring 36.
  • the substrate 10 moved to the heating and pressurizing mechanism 40 is pressure-bonded to the surface shape imparting mold 32 disposed on the holding surface of the flexible sheet 34 by a press machine using a hydraulic cylinder 44 (or an air cylinder) as a driving source.
  • the surface shape imparting mold 32 is heated and pressurized through the sandwiching surfaces of the pair of flexible sheets 34 by the heating plate 42 provided on the pressing surface of the press machine with the flexible sheet 34, and the surface shape imparting mold is provided on both surfaces of the substrate 10. 32 surface shape patterns are transferred.
  • the cooling and pressing mechanism 50 is the same as the heating and pressing mechanism 40 except that a cooling plate is provided instead of the heating plate 42.
  • the substrate 10 to which the surface shape pattern is transferred is cooled and solidified by the cooling plate, and peeled off from the surface shape imparting mold 32.
  • the cooling / pressurizing mechanism 50 may be an air cylinder or the like.
  • the chamber 30 After peeling, the chamber 30 further rotates and moves to the sheet take-out slide unit 60.
  • the chamber 30 finishes evacuation while moving to the sheet take-out slide unit 60, and the lid is opened.
  • the substrate 10 to which the surface shape pattern is transferred is unloaded from the sheet take-out slide unit 60, and the chamber 30 further rotates and moves to the sheet supply slide unit 20.
  • the surface-shaped optical member manufacturing apparatus 1 continuously manufactures the substrate 10 (surface-shaped optical member) to which the surface shape pattern is transferred by repeating this series of operations.
  • the pair of flexible sheets 34 has the surface shape imparting molds 32 on both the sandwiching surfaces and forms the surface shape patterns on both surfaces of the substrate, but is not limited thereto.
  • the pair of flexible sheets only needs to have a surface shape imparting mold on any one of the holding surfaces, and a substrate having a surface shape pattern transferred on only one surface can be produced.
  • Examples 1-27 Using the optical member manufacturing apparatus 1 shown in FIG. 1, an optical member substrate with a surface shape was manufactured in the vacuum state, pressurizing force, heating temperature, and heating time shown in Table 1.
  • the flexible sheet (brass) had a thickness of 1 mm, and a surface shape pattern was formed on a polycarbonate substrate (Idemitsu Unitech Co., Ltd.) having a thickness of 0.3 mm.
  • the cooling temperature was 20 ° C.
  • substrate was confirmed.
  • the “surface shape transfer region” is the area of the surface shape pattern of the surface shape imparting mold, and the “real transfer region” is possessed by the optical member with the surface shape imparted by the surface shape imparting die. This is the area of the surface shape pattern.

Abstract

A method for manufacturing an optical member having a surface shape includes: a step of sandwiching a substrate with a pair of flexible sheets having a surface shape forming die at least on one of the sandwiching surfaces; a step of bringing the space between the pair of flexible sheets into the vacuum state, applying heat and pressure to the sandwiching surfaces of the flexible sheets, and forming a surface shape pattern at least on one of the surfaces of the substrate; and a step of cooling the sandwiching surfaces of the pair of flexible sheets and solidifying the substrate having the surface shape pattern formed thereon.

Description

表面形状付き光学部材の製造方法及びその製造装置Manufacturing method of optical member with surface shape and manufacturing apparatus thereof
　本発明は、表面形状付き光学部材の製造方法及び表面形状付き光学部材の製造装置に関する。 The present invention relates to a method for manufacturing a surface-shaped optical member and a device for manufacturing a surface-shaped optical member.
　携帯電話等の小型液晶ディスプレイからパソコン及びテレビのような大型液晶ディスプレイまで、バックライトユニットの光源（例えば蛍光管又はＬＥＤ）の光を側面から取り入れ、画面上に導入する（面発光させる）ために導光板が幅広く使用されている。 For taking light from the light source (for example, fluorescent tube or LED) of the backlight unit from the side, from small liquid crystal displays such as cellular phones to large liquid crystal displays such as personal computers and televisions, and for introducing (light emission) on the screen Light guide plates are widely used.
　導光板には光学パターンと呼ばれる表面形状が付与されており、画面側面からの透過光をその表面形状により反射し、画面上に発光させることができる（特許文献１及び２）。市場の液晶ディスプレイの薄型化と共に、導光板にも薄さが要求されていた。 The light guide plate is provided with a surface shape called an optical pattern, and transmitted light from the side surface of the screen is reflected by the surface shape and can be emitted on the screen (Patent Documents 1 and 2). Along with the thinning of the liquid crystal display on the market, the light guide plate was also required to be thin.
　導光板等の表面形状付き光学部材は、光学部材用基板（例えばポリカーボネート導光板、拡散板等）に表面形状を転写することにより製造される。光学部材に表面形状転写を行なう方法としては、例えば射出成形方法、真空装置を用いた方法等が検討されている（特許文献３～９）。 An optical member with a surface shape such as a light guide plate is manufactured by transferring the surface shape to an optical member substrate (for example, a polycarbonate light guide plate, a diffusion plate, etc.). As a method for transferring the surface shape to the optical member, for example, an injection molding method, a method using a vacuum apparatus, and the like have been studied (Patent Documents 3 to 9).
　上述のように導光板はその薄肉化が要求されているが、例えば表面形状付き光学部材を射出成形で製造する場合、射出成形では表面形状付き光学部材の表面形状を効率よく且つ精度よく成形できない問題があった。具体的には、金型と基板の間に気泡が残ってしまうこと、金型端部まで樹脂が流れ込まないため転写率のバラツキが大きくなって歩留まりが悪くなる等の理由から、薄肉化及び連続運転が困難であった。 As described above, the light guide plate is required to be thin. For example, when an optical member with a surface shape is manufactured by injection molding, the surface shape of the optical member with a surface shape cannot be efficiently and accurately molded by injection molding. There was a problem. Specifically, for example, bubbles remain between the mold and the substrate, and because the resin does not flow into the mold end, the variation in the transfer rate increases and the yield deteriorates. Driving was difficult.
　また、表面形状付き光学部材を真空装置で製造する場合、基板に表面形状を転写する表面形状付与金型が厚く、真空、熱成形及び冷却の全てを行う際に加熱・冷却効率が悪く、時間が掛かるため、製造効率が悪いという問題があった。 In addition, when manufacturing an optical member with a surface shape with a vacuum apparatus, the surface shape imparting mold for transferring the surface shape to the substrate is thick, and when performing all of vacuum, thermoforming and cooling, the heating / cooling efficiency is poor and the time Therefore, there is a problem that the manufacturing efficiency is poor.
特開２００６－１５６３６８号公報JP 2006-156368 A 特開平８－１７９１３０号公報JP-A-8-179130 特開２００８－２３８４１号公報JP 2008-23841 A 特開２００８－２３８７６号公報JP 2008-23876 A 特開２００８－２３９２０号公報JP 2008-23920 A 特開２００６－１７５６１７号公報JP 2006-175617 A 特開平８－１６９０５０号公報JP-A-8-169050 特開２００６－１５９６４３号公報JP 2006-159543 A 特開２００７－９１３０６号公報JP 2007-91306 A
　本発明は、光学部材用基板への表面形状成形を、効率よく且つ精度よく行なうことができる表面形状付き光学部材の製造方法を提供することを目的とする。
　本発明は、光学部材用基板への表面形状成形を、効率よく且つ精度よく行なうことができる表面形状付き光学部材の製造装置を提供することを目的とする。 An object of this invention is to provide the manufacturing method of the optical member with a surface shape which can perform the surface shape shaping | molding to the board | substrate for optical members efficiently and accurately.
An object of this invention is to provide the manufacturing apparatus of the optical member with a surface shape which can perform the surface shape shaping | molding to the board | substrate for optical members efficiently and accurately.
　本発明によれば、以下の表面形状付き光学部材の製造方法等が提供される。
１．挟持面の少なくとも一面に表面形状付与金型を有する一対のフレキシブルシートで基板を挟持する工程、
　前記一対のフレキシブルシート間を真空にし、前記一対のフレキシブルシートの挟持面を加熱・加圧して、前記基板の少なくとも一面に表面形状パターンを形成する工程、及び
　前記一対のフレキシブルシートの挟持面を冷却して、前記表面形状パターンが形成された前記基板を固化する工程を含む表面形状付き光学部材の製造方法。
２．前記フレキシブルシートの挟持面を９０～２６０℃に加熱する１に記載の表面形状付き光学部材の製造方法。
３．前記フレキシブルシートの挟持面を５～１００℃に冷却する１又は２に記載の表面形状付き光学部材の製造方法。
４．前記フレキシブルシートの挟持面を０．５～５０ｋｇｆ／ｃｍ２に加圧する１～３のいずれかに記載の表面形状付き光学部材の製造方法。
５．基板を挟持する挟持面の少なくとも一面に表面形状付与金型を有する基板挟持手段と、
　前記基板を加熱・加圧して基板の少なくとも一面に表面形状パターンを形成する加熱・加圧手段と、
　前記基板を冷却して前記表面形状パターンが形成された前記基板を固化する冷却手段を具備する表面形状付き光学部材製造装置。 According to the present invention, the following method for producing a surface-shaped optical member is provided.
1. A step of sandwiching the substrate with a pair of flexible sheets having a surface shape imparting mold on at least one of the sandwich surfaces;
Forming a surface shape pattern on at least one surface of the substrate by cooling between the pair of flexible sheets; And the manufacturing method of the optical member with a surface shape including the process of solidifying the said board | substrate with which the said surface shape pattern was formed.
2. 2. The method for producing an optical member with a surface shape according to 1, wherein a holding surface of the flexible sheet is heated to 90 to 260 ° C.
3. 3. The method for producing an optical member with a surface shape according to 1 or 2, wherein a sandwiching surface of the flexible sheet is cooled to 5 to 100 ° C.
4). 4. The method for producing an optical member with a surface shape according to any one of 1 to 3, wherein the holding surface of the flexible sheet is pressurized to 0.5 to 50 kgf / cm 2 .
5). Substrate clamping means having a surface shape imparting mold on at least one of the clamping surfaces for clamping the substrate;
Heating / pressurizing means for heating / pressurizing the substrate to form a surface shape pattern on at least one surface of the substrate;
An apparatus for manufacturing an optical member with a surface shape, comprising cooling means for cooling the substrate to solidify the substrate on which the surface shape pattern is formed.
　本発明によれば、光学部材用基板への表面形状成形を、効率よく且つ精度よく行なうことができる表面形状付き光学部材の製造方法が提供できる。
　本発明によれば、光学部材用基板への表面形状成形を、効率よく且つ精度よく行なうことができる表面形状付き光学部材の製造装置が提供できる。 ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the optical member with a surface shape which can perform the surface shape shaping | molding to the board | substrate for optical members efficiently and accurately can be provided.
ADVANTAGE OF THE INVENTION According to this invention, the manufacturing apparatus of the optical member with a surface shape which can perform the surface shape shaping | molding to the board | substrate for optical members efficiently and accurately can be provided.
本発明に係る表面形状付き光学部材製造装置の一実施形態の概略上面図である。It is a schematic top view of one Embodiment of the optical member manufacturing apparatus with a surface shape which concerns on this invention. 本発明に係る表面形状付き光学部材製造装置の一実施形態の概略側面図である。It is a schematic side view of one Embodiment of the optical member manufacturing apparatus with a surface shape which concerns on this invention. 本発明に係る表面形状付き光学部材製造装置の一実施形態の概略正面図である。It is a schematic front view of one Embodiment of the optical member manufacturing apparatus with a surface shape which concerns on this invention. 加熱加圧機構に移動した基板が充填されたチャンバーの概略断面図である。It is a schematic sectional drawing of the chamber with which the board | substrate which moved to the heating-pressing mechanism was filled. 表面形状付与金型の表面形状付与領域及び表面形状付き光学部材の実転写範囲を示す図である。It is a figure which shows the actual transfer range of the surface shape provision area | region of a surface shape provision metal mold | die, and the optical member with a surface shape.
　本発明の表面形状付き光学部材の製造方法は、挟持面の少なくとも一面に表面形状付与金型を有する一対のフレキシブルシートで基板を挟持する工程、一対のフレキシブルシート間を真空にし、一対のフレキシブルシートの挟持面を加熱・加圧して、基板の少なくとも一面に表面形状パターンを形成する工程、及び一対のフレキシブルシートの挟持面を冷却して、表面形状パターンが形成された基板を固化する工程を含む。 The method of manufacturing an optical member with a surface shape according to the present invention includes a step of sandwiching a substrate with a pair of flexible sheets having a surface-shape imparting mold on at least one of the sandwiching surfaces, a vacuum between the pair of flexible sheets, and a pair of flexible sheets Forming a surface shape pattern on at least one surface of the substrate by heating and pressing the sandwiching surface of the substrate, and cooling the sandwiching surfaces of the pair of flexible sheets to solidify the substrate on which the surface shape pattern is formed. .
　本発明の表面形状付き光学部材の製造方法は、基板と表面形状付与金型との間に介在する空気を除いた状態で表面形状を転写（表面形状成形）するので、転写後の気泡の発生を抑制することができる。また、表面形状付与金型を有するフレキシブルシートを用いているため、表面形状付与金型の基板への密着性を高めることが可能になり、基板への転写精度を向上させることができる。さらに、本発明では表面形状付き光学部材を連続形成できるため、バッチ式の成形と比べて、表面形状付き光学部材を効率よく製造することができる。 In the method for producing an optical member with a surface shape according to the present invention, the surface shape is transferred (surface shape molding) in a state in which the air interposed between the substrate and the surface shape imparting mold is removed. Can be suppressed. Further, since the flexible sheet having the surface shape imparting mold is used, the adhesion of the surface shape imparting mold to the substrate can be improved, and the transfer accuracy to the substrate can be improved. Furthermore, since the optical member with a surface shape can be continuously formed in the present invention, the optical member with a surface shape can be efficiently manufactured as compared with batch-type molding.
　表面形状付き光学部材の製造に用いる基板の材料としては、ポリカーボネート（ＰＣ）、ポリエチレンテレフタラート（ＰＥＴ）、環状ポリオレフィン、アクリル、ポリスチレン（ＰＳ）等が挙げられる。
　上記基板の厚みは、通常０．０５～６．０ｍｍであり、好ましくは０．１～３．０ｍｍである。 Examples of the material of the substrate used for manufacturing the optical member with a surface shape include polycarbonate (PC), polyethylene terephthalate (PET), cyclic polyolefin, acrylic, polystyrene (PS), and the like.
The thickness of the substrate is usually 0.05 to 6.0 mm, preferably 0.1 to 3.0 mm.
　フレキシブルシートは、好ましくは熱伝導率が高い金属（例えば、アルミニウム、銅、真鍮等）のシートである。
　フレキシブルシートの厚みは、好ましくは０．５～３ｍｍである。このような薄いフレキシブルシートを用いることで、加熱及び冷却速度を高めることができ、サイクルタイムを大幅に短くすることができる。 The flexible sheet is preferably a sheet of metal (for example, aluminum, copper, brass, etc.) having high thermal conductivity.
The thickness of the flexible sheet is preferably 0.5 to 3 mm. By using such a thin flexible sheet, the heating and cooling rates can be increased, and the cycle time can be greatly shortened.
　一対のフレキシブルシートは、挟持面の少なくとも一面に表面形状付与金型を有する。
　表面形状付与金型が形成する表面形状パターンは、例えば光学部材が拡散板であれば、基板表面に当該パターンを転写することで光源からの入射光を集光及び／又は拡散することにより輝度向上及び輝度ムラを低減できる形状であれば特に限定されない。また、例えば光学部材が導光板であれば、基板表面に当該パターンを転写することで光源からの入射光を反射、出光等することにより輝度向上及び輝度ムラを低減できる形状であれば特に限定されない。尚、光学部材は拡散板及び導光板に限定されない。
　上記表面形状パターンとしては、リニア、三角錐、四角錐等の形状を有するプリズム、フレネルレンズ、レンチキュラーレンズ、半球状ドット等の形状が挙げられる。 The pair of flexible sheets has a surface shape imparting mold on at least one of the sandwiching surfaces.
For example, if the optical member is a diffuser plate, the surface shape pattern formed by the surface shape imparting mold improves the brightness by condensing and / or diffusing incident light from the light source by transferring the pattern onto the substrate surface. And if it is a shape which can reduce a brightness nonuniformity, it will not specifically limit. Further, for example, if the optical member is a light guide plate, there is no particular limitation as long as it is a shape that can improve luminance and reduce luminance unevenness by reflecting and emitting incident light from the light source by transferring the pattern onto the substrate surface. . The optical member is not limited to the diffusion plate and the light guide plate.
Examples of the surface shape pattern include shapes such as a prism, a Fresnel lens, a lenticular lens, and a hemispherical dot having shapes such as a linear shape, a triangular pyramid, and a quadrangular pyramid.
　表面形状付与金型を挟持面として一対のフレキシブルシートで基板を挟持した後、一対のフレキシブルシート間を真空にする。
　上記真空度は、通常－３０～－１００ｋＰａであり、好ましくは－５０～－１００ｋＰａである。 After sandwiching the substrate with a pair of flexible sheets using the surface shape imparting mold as a sandwiching surface, a vacuum is applied between the pair of flexible sheets.
The degree of vacuum is usually −30 to −100 kPa, preferably −50 to −100 kPa.
　一対のフレキシブルシート間を真空にした後、フレキシブルシートを加熱・加圧して基板の少なくとも一面に表面形状パターンを形成する。
　加熱温度は、通常９０～２６０℃である。基板が例えばポリカーボネート製シートである場合、加熱温度は、好ましくは１６０～２３０℃である。
　加圧圧力は、通常０．５～５０ｋｇｆ／ｃｍ２である。基板が例えばポリカーボネート製シートである場合、加圧圧力は、好ましくは１０～４０ｋｇｆ／ｃｍ２である。
　加熱・加圧処理時間は、通常１～６０秒であり、好ましくは５～１５秒である。 After evacuating between the pair of flexible sheets, the flexible sheet is heated and pressurized to form a surface shape pattern on at least one surface of the substrate.
The heating temperature is usually 90 to 260 ° C. When the substrate is a polycarbonate sheet, for example, the heating temperature is preferably 160 to 230 ° C.
The pressurizing pressure is usually 0.5 to 50 kgf / cm 2 . When the substrate is a polycarbonate sheet, for example, the pressurizing pressure is preferably 10 to 40 kgf / cm 2 .
The heating / pressurizing time is usually 1 to 60 seconds, preferably 5 to 15 seconds.
　表面形状パターンを形成した後、一対のフレキシブルシートを冷却して、前記表面形状パターンが形成された基板を固化し、フレキシブルシートから表面形状付き基板（表面形状付き光学部材）を剥離する。
　冷却温度としては、通常５～１００℃であり、好ましくは１０～３０℃である。また、冷却処理時間としては、通常１～６０秒であり、好ましくは３～１５秒である。 After forming the surface shape pattern, the pair of flexible sheets are cooled, the substrate on which the surface shape pattern is formed is solidified, and the substrate with surface shape (optical member with surface shape) is peeled from the flexible sheet.
The cooling temperature is usually 5 to 100 ° C., preferably 10 to 30 ° C. The cooling treatment time is usually 1 to 60 seconds, preferably 3 to 15 seconds.
　以上、加熱温度、加圧圧力、加熱・加圧処理時間、冷却温度、及び冷却処理時間を説明したが上記に限定されず、基板として用いる樹脂の軟化温度及び融解温度により適宜選択することができる。 The heating temperature, pressurizing pressure, heating / pressurizing treatment time, cooling temperature, and cooling treatment time have been described above, but are not limited to the above, and can be appropriately selected depending on the softening temperature and melting temperature of the resin used as the substrate. .
　本発明の表面形状付き光学部材の製造方法は、例えば図１～図３に示す表面形状付き光学部材製造装置を用いることにより実施できる。
　図１は本発明に係る表面形状付き光学部材製造装置の一実施形態の概略上面図であり、図２は本発明に係る表面形状付き光学部材製造装置の一実施形態の概略側面図であり、図３は本発明に係る表面形状付き光学部材製造装置の一実施形態の概略正面図である。 The method for producing a surface-shaped optical member of the present invention can be carried out, for example, by using a surface-shaped optical member manufacturing apparatus shown in FIGS.
FIG. 1 is a schematic top view of an embodiment of an optical member manufacturing apparatus with a surface shape according to the present invention. FIG. 2 is a schematic side view of an embodiment of an optical member manufacturing apparatus with a surface shape according to the present invention. FIG. 3 is a schematic front view of an embodiment of the optical member manufacturing apparatus with a surface shape according to the present invention.
　図１～図３の表面形状付き光学部材製造装置１は、ロータリー式真空転写装置であり、基板１０を供給するシート供給スライドユニット２０、基板１０を挟持するフレキシブルシート（基板挟持手段）を備えたチャンバー３０、加熱して表面形状転写する加熱加圧機構４０（加熱手段）、チャンバー３０と表面形状転写した基板を冷却固化して、チャンバー３０からの基板１０の剥離を容易にする冷却加圧機構５０（冷却手段）、及び表面形状転写した基板を取り出すシート取り出しスライドユニット６０を同一平面上に備えている。
　シート供給スライドユニット２０、加熱加圧機構４０、冷却加圧機構５０及びシート取り出しスライドユニット６０は、間欠回転するチャンバー３０の回転軸を中心とした同心円上にこの順に配されている。 The surface-shaped optical member manufacturing apparatus 1 shown in FIGS. 1 to 3 is a rotary vacuum transfer apparatus, and includes a sheet supply slide unit 20 that supplies a substrate 10 and a flexible sheet (substrate clamping means) that clamps the substrate 10. A chamber 30, a heating and pressing mechanism 40 (heating means) for transferring the surface shape by heating, and a cooling and pressing mechanism for easily separating the substrate 10 from the chamber 30 by cooling and solidifying the chamber 30 and the substrate having the transferred surface shape. 50 (cooling means) and a sheet take-out slide unit 60 for taking out the substrate whose surface shape has been transferred are provided on the same plane.
The sheet supply slide unit 20, the heating / pressurizing mechanism 40, the cooling / pressurizing mechanism 50, and the sheet take-out slide unit 60 are arranged in this order on a concentric circle around the rotation axis of the chamber 30 that rotates intermittently.
　基板１０は、シート供給スライドユニット２０から供給され、チャンバー３０内に充填される。基板１０が充填されたチャンバー３０は、サーボモーター等を駆動源として回転軸を中心に回転し、加熱加圧機構４０まで回転する。
　チャンバー３０は、加熱加圧機構４０までの回転中に蓋が閉じられ、真空バルブによって真空引きが開始され、チャンバー３０内は真空となる。 The substrate 10 is supplied from the sheet supply slide unit 20 and filled in the chamber 30. The chamber 30 filled with the substrate 10 is rotated about the rotation axis by using a servo motor or the like as a drive source and is rotated to the heating and pressurizing mechanism 40.
The chamber 30 is closed during rotation to the heating and pressurizing mechanism 40, and evacuation is started by a vacuum valve, and the inside of the chamber 30 is evacuated.
　図４は、加熱加圧機構４０に移動した基板１０が充填されたチャンバー３０の概略断面図である。
　基板１０は、表面形状付与金型３２を挟持面にして、一対のフレキシブルシート３４（基板挟持手段）で挟持されている。チャンバー３０内はＯ－リング３６によって真空エリア３８を形成している。 FIG. 4 is a schematic cross-sectional view of the chamber 30 filled with the substrate 10 moved to the heating and pressurizing mechanism 40.
The substrate 10 is sandwiched between a pair of flexible sheets 34 (substrate sandwiching means) with the surface shape imparting mold 32 as a sandwiching surface. A vacuum area 38 is formed in the chamber 30 by an O-ring 36.
　加熱加圧機構４０に移動した基板１０は、油圧シリンダー４４（又はエアーシリンダー）を駆動源としたプレス機により、フレキシブルシート３４の挟持面に配置された表面形状付与金型３２と圧着する。プレス機がフレキシブルシート３４との圧着面に備える加熱板４２によって、一対のフレキシブルシート３４の挟持面を通して表面形状付与金型３２は加熱及び加圧され、基板１０の両面には表面形状付与金型３２の表面形状パターンが転写される。 The substrate 10 moved to the heating and pressurizing mechanism 40 is pressure-bonded to the surface shape imparting mold 32 disposed on the holding surface of the flexible sheet 34 by a press machine using a hydraulic cylinder 44 (or an air cylinder) as a driving source. The surface shape imparting mold 32 is heated and pressurized through the sandwiching surfaces of the pair of flexible sheets 34 by the heating plate 42 provided on the pressing surface of the press machine with the flexible sheet 34, and the surface shape imparting mold is provided on both surfaces of the substrate 10. 32 surface shape patterns are transferred.
　表面形状パターン転写後、チャンバー３０はさらに回転して、冷却加圧機構５０まで移動する。冷却加圧機構５０は加熱板４２の代わりに冷却板を備えるほかは加熱加圧機構４０と同様である。表面形状パターンが転写された基板１０は冷却板によって冷却固化され、表面形状付与金型３２から剥離する。
　尚、冷却加圧機構５０は、エアーシリンダー等であってもよい。 After the transfer of the surface shape pattern, the chamber 30 further rotates and moves to the cooling and pressing mechanism 50. The cooling and pressing mechanism 50 is the same as the heating and pressing mechanism 40 except that a cooling plate is provided instead of the heating plate 42. The substrate 10 to which the surface shape pattern is transferred is cooled and solidified by the cooling plate, and peeled off from the surface shape imparting mold 32.
The cooling / pressurizing mechanism 50 may be an air cylinder or the like.
　剥離後、チャンバー３０はさらに回転し、シート取り出しスライドユニット６０まで移動する。チャンバー３０はシート取り出しスライドユニット６０までの移動中に真空引きを終了し、蓋が開放される。
　表面形状パターンが転写された基板１０は、シート取り出しスライドユニット６０から搬出され、チャンバー３０は、さらに回転しシート供給スライドユニット２０まで移動する。 After peeling, the chamber 30 further rotates and moves to the sheet take-out slide unit 60. The chamber 30 finishes evacuation while moving to the sheet take-out slide unit 60, and the lid is opened.
The substrate 10 to which the surface shape pattern is transferred is unloaded from the sheet take-out slide unit 60, and the chamber 30 further rotates and moves to the sheet supply slide unit 20.
　表面形状付き光学部材製造装置１は、この一連の動作を繰り返し行うことにより、表面形状パターンが転写された基板１０（表面形状付き光学部材）を連続して製造する。
　尚、本実施形態では、一対のフレキシブルシート３４は、挟持面の両方に表面形状付与金型３２を有し、基板の両面に表面形状パターンを形成するが、これに限定されない。本発明では、一対のフレキシブルシートは、その挟持面のいずれか一面に表面形状付与金型を有すればよく、片面のみに表面形状パターンが転写された基板を製造することもできる。 The surface-shaped optical member manufacturing apparatus 1 continuously manufactures the substrate 10 (surface-shaped optical member) to which the surface shape pattern is transferred by repeating this series of operations.
In the present embodiment, the pair of flexible sheets 34 has the surface shape imparting molds 32 on both the sandwiching surfaces and forms the surface shape patterns on both surfaces of the substrate, but is not limited thereto. In the present invention, the pair of flexible sheets only needs to have a surface shape imparting mold on any one of the holding surfaces, and a substrate having a surface shape pattern transferred on only one surface can be produced.
　以下、本発明の実施例を基に詳細に説明するが、本発明はその要旨を越えない限り、以下の実施例に限定されない。 Hereinafter, the present invention will be described in detail based on examples of the present invention, but the present invention is not limited to the following examples unless it exceeds the gist.
実施例１～２７
　図１に示す光学部材製造装置１を用いて、表１に示す真空状態、加圧力、加熱温度及び加熱時間で表面形状付き光学部材用基板を製造した。尚、実施例１～２７では、フレキシブルシート（黄銅製）の厚みは１ｍｍであり、０．３ｍｍ厚のポリカーボネート製基板（出光ユニテック株式会社製）に表面形状パターンを形成した。冷却温度は２０℃とした。また、製造の際の表面形状付与金型と基板との間の気泡の有無について確認した。 Examples 1-27
Using the optical member manufacturing apparatus 1 shown in FIG. 1, an optical member substrate with a surface shape was manufactured in the vacuum state, pressurizing force, heating temperature, and heating time shown in Table 1. In Examples 1 to 27, the flexible sheet (brass) had a thickness of 1 mm, and a surface shape pattern was formed on a polycarbonate substrate (Idemitsu Unitech Co., Ltd.) having a thickness of 0.3 mm. The cooling temperature was 20 ° C. Moreover, the presence or absence of the bubble between the surface shape provision metal mold | die at the time of manufacture and a board | substrate was confirmed.
　製造した実施例１～２７の表面形状付き光学部材用基板の転写率を評価した。結果を表１に示す。
　上記転写率は、図５に示す実転写範囲及び表面形状転写領域から、以下の式を基に算出した。
　　転写率［％］＝（実転写範囲／表面形状転写領域）×１００ The transfer rate of the manufactured optical member substrates with surface shapes of Examples 1 to 27 was evaluated. The results are shown in Table 1.
The transfer rate was calculated based on the following formula from the actual transfer range and surface shape transfer region shown in FIG.
Transfer rate [%] = (actual transfer range / surface shape transfer area) × 100
　尚、「表面形状転写領域」とは、表面形状付与金型が有する表面形状パターンの面積であり、「実転写領域」とは、表面形状付与金型により付与された表面形状付き光学部材が有する表面形状パターンの面積である。 The “surface shape transfer region” is the area of the surface shape pattern of the surface shape imparting mold, and the “real transfer region” is possessed by the optical member with the surface shape imparted by the surface shape imparting die. This is the area of the surface shape pattern.
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000001
　上記に本発明の実施形態及び／又は実施例を幾つか詳細に説明したが、当業者は、本発明の新規な教示及び効果から実質的に離れることなく、これら例示である実施形態及び／又は実施例に多くの変更を加えることが容易である。従って、これらの多くの変更は本発明の範囲に含まれる。
　この明細書に記載の文献の内容を全てここに援用する。 Although several embodiments and / or examples of the present invention have been described in detail above, those skilled in the art will appreciate that these exemplary embodiments and / or embodiments are substantially without departing from the novel teachings and advantages of the present invention. It is easy to make many changes to the embodiment. Accordingly, many of these modifications are within the scope of the present invention.
The entire contents of the documents described in this specification are incorporated herein by reference.

Claims (5)

  1. 　挟持面の少なくとも一面に表面形状付与金型を有する一対のフレキシブルシートで基板を挟持する工程、
    　前記一対のフレキシブルシート間を真空にし、前記一対のフレキシブルシートの挟持面を加熱・加圧して、前記基板の少なくとも一面に表面形状パターンを形成する工程、及び
    　前記一対のフレキシブルシートの挟持面を冷却して、前記表面形状パターンが形成された前記基板を固化する工程を含む表面形状付き光学部材の製造方法。     A step of sandwiching the substrate with a pair of flexible sheets having a surface shape imparting mold on at least one of the sandwich surfaces;
    Forming a surface shape pattern on at least one surface of the substrate by cooling between the pair of flexible sheets; And the manufacturing method of the optical member with a surface shape including the process of solidifying the said board | substrate with which the said surface shape pattern was formed.
  2. 　前記フレキシブルシートの挟持面を９０～２６０℃に加熱する請求項１に記載の表面形状付き光学部材の製造方法。 The method for producing an optical member with a surface shape according to claim 1, wherein the holding surface of the flexible sheet is heated to 90 to 260 ° C.
  3. 　前記フレキシブルシートの挟持面を５～１００℃に冷却する請求項１又は２に記載の表面形状付き光学部材の製造方法。 The method for producing an optical member with a surface shape according to claim 1 or 2, wherein a sandwiching surface of the flexible sheet is cooled to 5 to 100 ° C.
  4. 　前記フレキシブルシートの挟持面を０．５～５０ｋｇｆ／ｃｍ２に加圧する請求項１～３のいずれかに記載の表面形状付き光学部材の製造方法。 The method for producing an optical member with a surface shape according to any one of claims 1 to 3, wherein the holding surface of the flexible sheet is pressurized to 0.5 to 50 kgf / cm 2 .
  5. 　基板を挟持する挟持面の少なくとも一面に表面形状付与金型を有する基板挟持手段と、
    　前記基板を加熱・加圧して基板の少なくとも一面に表面形状パターンを形成する加熱・加圧手段と、
    　前記基板を冷却して前記表面形状パターンが形成された前記基板を固化する冷却手段を具備する表面形状付き光学部材製造装置。     Substrate clamping means having a surface shape imparting mold on at least one of the clamping surfaces for clamping the substrate;
    Heating / pressurizing means for heating / pressurizing the substrate to form a surface shape pattern on at least one surface of the substrate;
    An apparatus for manufacturing an optical member with a surface shape, comprising cooling means for cooling the substrate to solidify the substrate on which the surface shape pattern is formed.
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