KR101686465B1 - Optical sheet and method of manufacturing the same, multi-optical sheet using the optical sheet - Google Patents

Optical sheet and method of manufacturing the same, multi-optical sheet using the optical sheet Download PDF

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Publication number
KR101686465B1
KR101686465B1 KR1020150054539A KR20150054539A KR101686465B1 KR 101686465 B1 KR101686465 B1 KR 101686465B1 KR 1020150054539 A KR1020150054539 A KR 1020150054539A KR 20150054539 A KR20150054539 A KR 20150054539A KR 101686465 B1 KR101686465 B1 KR 101686465B1
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South Korea
Prior art keywords
optical sheet
layer
light
pattern
optical
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KR1020150054539A
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Korean (ko)
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KR20160123834A (en
Inventor
안준원
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주식회사 케이에이피에스
안준원
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Priority to KR1020150054539A priority Critical patent/KR101686465B1/en
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    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL 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
    • G02F1/00—Devices 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
    • G02F1/01—Devices 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 
    • G02F1/13—Devices 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
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/0001—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems
    • G02B6/0011—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings specially adapted for lighting devices or systems the light guides being planar or of plate-like form
    • G—PHYSICS
    • G02—OPTICS
    • G02F—OPTICAL 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
    • G02F1/00—Devices 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
    • G02F1/01—Devices 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 
    • G02F1/13—Devices 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
    • G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
    • G02F1/1333—Constructional arrangements; Manufacturing methods
    • G02F1/1335—Structural association of cells with optical devices, e.g. polarisers or reflectors
    • G02F1/1336—Illuminating devices
    • G02F1/133615—Edge-illuminating devices, i.e. illuminating from the side

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  • Physics & Mathematics (AREA)
  • Nonlinear Science (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Mathematical Physics (AREA)
  • Chemical & Material Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Optical Elements Other Than Lenses (AREA)

Abstract

The present disclosure relates to a substrate comprising: a substrate layer; And a light modulating layer having a protrusion on one surface of the substrate layer, wherein the protrusion of the light modulating layer comprises a spacer integrated with the light modulating pattern and the light modulating pattern, and an optical sheet, And a composite optical sheet using the optical sheet.

Description

TECHNICAL FIELD [0001] The present invention relates to an optical sheet, a method of manufacturing the same, a composite optical sheet using the optical sheet,

Disclosure relates to an optical sheet having a light-modulating layer as a whole, and more particularly to an optical sheet having a spacer in a light-modulating layer, a method of manufacturing the same, and a composite optical sheet using the optical sheet.

Herein, the background art relating to the present disclosure is provided, and these are not necessarily meant to be known arts.

A liquid crystal display (LCD) is a device for displaying an image by injecting liquid crystal between two glass plates and applying power to the upper and lower glass plate electrodes to change the arrangement of liquid crystal molecules in each pixel. Unlike a cathode ray tube (CRT), a plasma display panel (PDP) or the like, a display using a liquid crystal display device is not usable in a place where there is no light because the display itself is non-luminous. In order to compensate for these drawbacks, a light source assembly that is uniformly irradiated on the information display surface is mounted for the purpose of enabling use in a dark place.

The light source assembly used in the liquid crystal display device is divided into two types. The first is an edge type light source assembly that provides light at the side of the liquid crystal display device, and the second is a direct light type light source assembly that provides light directly at the rear side of the liquid crystal display device. In some edge type light source assemblies, a light guide plate is provided so that light emitted from a light source is irradiated upward, and at least one optical sheet is provided above the light guide plate to control optical characteristics of light passing through the light guide plate. In the case of some direct type light source assemblies, a diffusion plate is provided to reduce the light lines of light emitted from the light source, and at least one optical sheet is provided to control the optical characteristics of light passing through the diffusion plate.

1 is a sectional view schematically showing an example of an edge light source assembly.

The edge type light source assembly 10 includes a light source 11, a light guide plate 12, a diffusion sheet 13, and prism sheets 14 and 15. As liquid crystal displays evolve thinner and brighter, thin and bright light source assemblies are needed. Optical sheets such as the light guide plate 12, the diffusion sheet 13 and the prism sheets 14 and 15 have been developed to have the same function but to be thinner in order to make the light source assembly thin and bright. Particularly, the optical sheet includes a base layer and a light modulating layer formed on one surface of the base layer. The thickness of the optical sheet is reduced by using a thin PET layer used as a substrate layer. However, when the thickness of the substrate layer is reduced, there is a limitation in reducing the thickness of the optical sheet by reducing the thickness of the base layer due to the problem of worsening of defects such as wrinkles and curls. In recent years, in order to reduce the thickness of the optical sheet, a composite optical sheet in which two optical sheets are attached with an adhesive has been developed. For example, two prism sheets 14 and 15 shown in Fig. 1 may be attached to form a composite optical sheet. However, in the composite optical sheet to which the two optical sheets are attached, a sufficient air layer is required between the optical sheets to be bonded so that the underlying optical sheet maintains its original function.

2 is a perspective view showing an example of a composite optical sheet in which two prism sheets are bonded.

The composite optical sheet 20 includes a first prism sheet 21 and a second prism sheet 22. The first prism sheet 21 includes a first base layer 23, a first optical modulation layer 25 having a protrusion 24, and an adhesive layer 26. The second prism sheet 22 includes a second base layer 27 and a second optical modulation layer 29 having a protrusion 28. The composite optical sheet 20 is made by bonding the projecting portion 28 of the second prism sheet 22 to the adhesive layer 26 of the first prism sheet 21. [ The height of the protrusion of the optical modulating layer of the prism sheet is not less than 5 μm and the protrusion 28 of the second prism sheet 22 is bonded to the adhesive layer 26 of the first prism sheet 21, (30) between the adhesive layer (26) of the first prism sheet (21) and the second light modulating layer (29) of the second prism sheet (22) due to the height (30) Is formed. The height of the protrusion of the light modulating layer can generally be measured by the distance between the apex of the protrusion and the flat surface of the light modulating layer. However, if the flat surface of the light modulating layer is uncertain, it can be measured as the distance between the flat surface of the substrate layer facing the surface on which the light modulating layer of the substrate layer is located and the apex of the protruding portion.

3 is a brief sectional view showing an example of a composite optical sheet using a diffusion sheet and a diffusion sheet.

3 (a) is a simplified sectional view showing an example of a conventional diffusion sheet. The diffusion sheet 40 includes a base layer 41, and a light modulating layer 43 having a projection 42. In the conventional diffusion sheet 40, the projecting portion 42 of the light modulating layer 43 is made by a diffusion bead or a diffusion pattern. However, the value of the central line average height (Ra) of the projected portion 42 of the light modulating layer 43 in the conventional diffusion sheet 40 is 10um or less.

Fig. 3 (b) is a simplified cross-sectional view showing an example of the composite optical sheet 50 using the conventional diffusion sheet 40. Fig. In the case of forming the composite optical sheet 50 by bonding the projecting portion 42 of the diffusion sheet 40 to another optical sheet 60 having the adhesive layer 61, unlike the prism sheet, The The air layer 51 is not formed well because the height of the projecting portion 42 is small. There is a problem that the diffusion sheet 40 bonded to the composite optical sheet 50 can not perform the diffusion function because the air layer 51 is not sufficiently formed.

In the present disclosure, when forming a composite optical sheet using an optical sheet including a light modulating layer having a protruding portion with an Ra value of 10um or less, it is aimed to solve the problem that it is difficult to form an air layer between two optical sheets.

This will be described later in the Specification for Enforcement of the Invention.

SUMMARY OF THE INVENTION Herein, a general summary of the present disclosure is provided, which should not be construed as limiting the scope of the present disclosure. of its features).

According to one aspect of the present disclosure, a substrate layer; And a light modulating layer having a protrusion on one surface of the base layer, wherein the protrusion of the light modulating layer includes a spacer integrated with the light modulating pattern and the light modulating pattern.

According to another aspect of the present disclosure, there is provided a method of manufacturing a light modulating device, comprising: coating a photoregister (PR) on a light modulating layer in an optical sheet having a light modulating layer including a light modulating pattern; Irradiating the light using a mask having a predetermined pattern toward the PR layer coated on the light modulating layer in the optical sheet having the light modulating layer; Etching to form a primary master having a PR-shaped spacer layer on the light modulating layer; Fabricating a secondary master including an engraved pattern in which a light modulation pattern and a spacer shape are integrated from a primary master; Forming a light modulation layer including a projected portion in which a light modulation pattern and a spacer shape are integrated with each other by filling the engraved pattern of the secondary master with a photocurable resin; And bonding the base layer to the flat surface of the optical modulation layer.

According to another aspect of the present disclosure, a light modulating layer having a base layer, a light modulating pattern and a first projection including a spacer integrated with the light modulating pattern is laminated in order A first optical sheet; And a second optical sheet in which a light modulating layer having a second projecting portion, a base layer and an adhesive layer are laminated in this order, wherein the spacer of the first optical sheet is bonded to the adhesive layer of the second optical sheet A composite optical sheet is provided.

This will be described later in the Specification for Enforcement of the Invention.

1 is a sectional view schematically showing an example of an edge light source assembly,
2 is a perspective view showing an example of a composite optical sheet in which two prism sheets are bonded,
3 is a simplified sectional view showing an example of a composite optical sheet using a diffusion sheet and a diffusion sheet,
4 is a schematic cross-sectional view of an example of an optical sheet according to the present disclosure,
5 is a perspective view of an example of an optical sheet according to the present disclosure,
6 is a perspective view and a top view showing an example of a spacer included in an optical sheet according to the present disclosure,
7 is a schematic sectional view showing an example of a method of manufacturing an optical sheet according to the present disclosure,
8 is a perspective view showing an example of a composite optical sheet using an optical sheet according to the present disclosure;

The present disclosure will now be described in detail with reference to the accompanying drawings.

4 is a schematic cross-sectional view of an example of an optical sheet according to the present disclosure;

The optical sheet 100 according to the present disclosure includes a base layer 110 and a light modulating layer 120 having a projection 123 on one side of the base layer 110. [ The substrate layer 110 includes a film made of a plastic material using PET, PP, PC, PMMA, etc., and a plate like a diffusion plate and a light guide plate. The protrusion 123 of the light modulation layer 120 includes a light modulation pattern 121 and a spacer 122 integrated with the light modulation pattern. The optical modulation pattern 122 and the spacer 121 are made of the same material and there is no interface between the spacer 121 and the light modulation pattern 122. [ When the optical modulation pattern 122 and the spacer 121 are made of the same material, refraction, interfacial reflection and scattering due to a difference in refractive index are less likely to occur, which is advantageous for exhibiting relatively excellent optical characteristics. In addition, physical properties such as shrinkage and expansion ratio are the same, so that they can have relatively stable mechanical properties. It is preferable that the spacers 121 are irregularly arranged in the light modulation layer 120. The height of the spacer 121 and the light modulation pattern 122 can be measured based on the flat surface of the light modulation layer. The height 124 of the spacer 121 is preferably at least 2 mu m higher than the maximum height 125 of the light modulation pattern 122. [ However, in order to stably support the optical sheet placed on the spacer 121, the height 124 of the spacer 121 is preferably 100um or less. The Ra value of the optical modulation pattern 120 is preferably 10um or less. When the Ra value of the light modulation pattern is sufficiently high as in the case of a light modulation pattern which is a protruding portion of a prism sheet, a spacer for forming an air layer is not required in forming a composite optical sheet. 4 shows a diffusion sheet as an example of an optical sheet having an Ra value of 10um or less in the light modulation pattern 123. However, the present invention is not limited thereto, and any optical sheet having an Ra value of the light modulation pattern of 10um or less may be included in the present disclosure .

5 is a perspective view of an example of an optical sheet according to the present disclosure;

FIG. 5 clearly shows that the spacers 121 in the optical sheet 100 according to the present disclosure are irregularly arranged in the light modulation layer 120. When the unit area of the optical sheet 100 is 1, the area occupied by the spacer 121 in the optical sheet 100 is preferably 0.4 or less. The reason why the area occupied by the spacer 121 in the optical sheet 100 is preferably 0.4 or less is described in Fig.

6 is a perspective view and a cross-sectional view showing an example of a spacer included in the optical sheet according to the present disclosure;

The spacer may be a cylinder, a triangular prism, a quadrangular prism, a triangular pyramid, or a quadrilateral, as shown in a perspective view of FIG. 6 (a). Preferably, the area of the lower portion cut along the AA 'line is larger than the area of the upper portion cut along BB', such as cone, triangular, and quadrangular pyramid. The reason will be described in Fig. For example, FIG. 6 (b) is a section of a lower portion cut along AA 'of a triangular pyramid, and FIG. 6 (c) is a cross section of an upper portion cut along BB' of a triangular pyramid. The shape of the cross section is triangular. When the area of the cross section is compared, the area of the cross section of the lower part is larger than the area of the cross section of the upper part. It is also preferred that the area 130 at the lowermost portion of the spacer does not exceed a maximum diameter of 1 mm. More specifically, it is possible to achieve the object of using the spacer while minimizing the problem of visually recognizing the spacer when the thickness is 200um or less. The shape of the spacer is, for example, a cylinder, a triangular prism, a quadrangular prism, a triangular pyramid, and a quadrilateral. Also, the shape of the section cut along the line AA 'may be at least one of circular, triangular, and polygonal such as a rectangle.

7 is a schematic cross-sectional view showing an example of a method of manufacturing an optical sheet according to the present disclosure.

7 (a), a liquid photoreceptor PR is coated on a light modulation layer 210 in an optical sheet 200 having a light modulation layer 210 including a light modulation pattern 211, Thereby forming a resistive layer 220. For example, when the light modulation layer is a diffusion layer, the light modulation pattern may be a protrusion protruding from the surface by a diffusion bead or a diffusion pattern. Examples of a method of coating a photoresist on an optical sheet having a light modulating layer include a dip coating method, an air knife coating method, a curtain coating method, a roller coating method, a wire bar coating method, a gravure coating method and an extrusion coating method Can be coated. 7 (b), a mask 230 having a predetermined pattern toward the photoregistering layer 220 coated on the optical modulation layer 210 in the optical sheet 200 having the optical modulation layer 210 To illuminate the light (240). 7 (c), a primary master 260 having a spacer-shaped photoresist layer 250 is formed on the optical modulation layer 210. A secondary master 270 including an engraved pattern 273 in which the light modulation pattern 271 and the spacer 272 are integrated with each other is fabricated from the primary master 260 as shown in FIG. 7E, the recessed pattern 273 of the secondary master 270 is filled with a photo-curable resin so that the light modulation including the protrusion 283 in which the light modulation pattern 281 and the spacer 282 are integrated is performed, Layer 280 is formed. The base layer 290 is bonded to the flat surface 284 of the optical modulation layer 280 as shown in Fig. 7 (f) so that the protrusion 283, in which the optical modulation pattern 281 and the spacer 282 are integrated, An optical sheet 300 including a light modulation layer 280 and a base layer 290 is fabricated. The engraving pattern of the secondary master may be filled with a thermosetting resin instead of the photocurable resin.

8 is a perspective view showing an example of a composite optical sheet using an optical sheet according to the present disclosure.

The composite optical sheet 400 using the optical sheet according to the present disclosure includes a second optical modulation layer 422 having a first base layer 411, a first optical sheet 410 and a second projection 421, And a second optical sheet 420 in which a second base layer 423 and an adhesive layer 424 are stacked in this order and the spacer 413 of the first optical sheet 410 is bonded to the second optical sheet 420 And is bonded to the adhesive layer (424). The second optical modulating layer 422 of the second optical sheet 420 may not include the protruding portion 421. [ An optical sheet having a light modulating layer that does not include projections is generally known as a reflective polarizing film, and products such as 3M DBEF are available. When the unit area of the first optical sheet 410 is 1, the area occupied by the spacer 413 in the first optical sheet 410 is preferably 0.4 or less. The reason for this is that the spacer 413 is bonded to the second optical sheet 420 so that an air layer is formed between the first optical sheet 410 and the second optical sheet 420 when the area occupied by the spacer 413 is large This is because the shielding property is reduced when the first optical sheet 410 is a diffusion sheet. It is preferable that the area of the lower portion of the spacer 413 is larger than the area of the upper portion as described with reference to FIG. 6, because the shielding force decreases as the area where the spacer 413 joins with the second optical sheet 420 is larger for the same reason . Table 1 below shows the result of simulating the correlation between the area of the spacer and the shielding property.

The area occupied by the spacer in the optical sheet
(The unit area of the optical sheet is set to 1) Shielding characteristics 0 Very good 0.1 Very good 0.2 good 0.3 good 0.4 usually 0.5 Shielding power shortage

Various embodiments of the present disclosure will be described below.

(1) a base layer; And a light modulating layer having a protrusion on one surface of the base layer, wherein the protrusion of the light modulating layer includes a spacer integrated with the light modulating pattern and the light modulating pattern.

(2) Ra value of 10um or less Wherein the optical sheet is an optical sheet.

(3) An optical sheet characterized in that the optical modulation pattern and the spacer are formed of the same material.

(4) The optical sheet is characterized in that the spacers are irregularly arranged in the light modulating layer.

(5) The optical sheet according to (5), wherein the cross-sectional shape of the spacer is at least one of circular, elliptical, triangular, and polygonal.

(6) The optical sheet according to any one of (1) to (5), wherein the spacer is smaller as viewed from above when the area is from the bottom to the top.

(7) The optical sheet according to any one of (1) to (4), wherein the height of the spacer is at least 2 μm higher than the maximum height of the light modulation pattern of the light modulation layer.

(8) coating a photoregister (PR) on the optical modulation layer in an optical sheet having a light modulation layer including a light modulation pattern; Irradiating the light using a mask having a predetermined pattern toward the PR layer coated on the light modulating layer in the optical sheet having the light modulating layer; Etching to form a primary master having a PR-shaped spacer layer on the light modulating layer; Fabricating a secondary master including an engraved pattern in which a light modulation pattern and a spacer shape are integrated from a primary master; Forming a light modulation layer including a projected portion in which a light modulation pattern and a spacer shape are integrated with each other by filling the engraved pattern of the secondary master with a photocurable resin; And bonding the base layer to the flat surface of the optical modulation layer.

(9) An optical sheet manufacturing method, wherein the Ra value of the light modulation pattern is 10um or less.

(10) A method of coating PR on an optical sheet having a light modulating layer can be carried out by various methods such as dip coating, air knife coating, curtain coating, roller coating, wire bar coating, gravure coating, extrusion coating, And a die coating method.

(11) a first optical sheet in which a base layer, a light modulation layer and a light modulation layer having a first projection including a spacer integrated with the light modulation pattern are stacked in order; And a second optical sheet in which a light modulating layer having a second projecting portion, a base layer and an adhesive layer are laminated in this order, wherein the spacer of the first optical sheet is bonded to the adhesive layer of the second optical sheet Composite optical sheet.

(12) A composite optical sheet characterized in that the Ra value of the light modulation pattern is 10um or less.

(13) A composite optical sheet characterized in that the height of the spacer is at least 2 [mu] m higher than the maximum height of the light modulation pattern.

According to the optical sheet according to the present disclosure, when a composite optical sheet is formed using an optical sheet having a low height of protrusions, an optical sheet laminated on the optical sheet having a low height of protrusions and an optical sheet having a low height of protrusions The air layer can be easily formed.

40, 100: Optical sheet
20, 50, 400: composite optical sheet
121, 282, 413: spacers

Claims (14)

delete delete delete delete delete delete delete Coating a photoregister (PR) on a light modulating layer of an optical sheet having a light modulating layer including a light modulating pattern;
Irradiating light using a mask having a predetermined pattern toward a PR layer coated on a light modulating layer of an optical sheet having an optical modulating layer;
Etching to form a primary master having a spacer layer-shaped PR layer on a light modulating layer of an optical sheet having a light modulating layer;
Fabricating a secondary master including an engraved pattern in which a light modulation pattern replicated in an optical sheet from a primary master and a spacer shape replicated in a PR layer are integrated;
Forming a light modulation layer including a projected portion in which a light modulation pattern and a spacer shape are integrated with each other by filling the engraved pattern of the secondary master with a photocurable resin; And,
And bonding the base layer to the flat surface of the optical modulation layer. The method of claim 8,
Wherein the Ra value of the light modulation pattern is 10um or less. The method of claim 8,
The method of coating PR on the optical sheet having the optical modulating layer can be carried out by various methods such as dip coating method, air knife coating method, curtain coating method, roller coating method, wire bar coating method, gravure coating method, extrusion coating method, Wherein the optical sheet is manufactured by a method comprising the steps of: delete delete delete delete
KR1020150054539A 2015-04-17 2015-04-17 Optical sheet and method of manufacturing the same, multi-optical sheet using the optical sheet KR101686465B1 (en)

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KR20110136645A (en) * 2010-06-15 2011-12-21 엘지디스플레이 주식회사 Backlight unit and liquid crystal display device having the same
KR101278347B1 (en) * 2012-08-22 2013-06-25 주식회사 세코닉스 A Optical Film Having Amorphous Pattern and a Method for Manufacturing the Same

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