200941089 九、發明說明： 【發明所屬之技術領域】 本發明揭露一種製造光學膜之方法，尤其是製造TFT_ LCD之增亮膜之方法、及所製成之增亮膜，本發明亦揭露 利用此一方法製造光學膜/增亮膜所使用之壓印器。 【先前技術】 TFT-LCD是用於如筆記型電腦、液晶電視等顯示裝置， 於市場中有廣大需求。由於TFT-LCD無法自行發光，一般 © 是採用背光模組來提供顯示光源。TFT-LCD的背光模組分 成侧光式及直下式兩種結構：側光式結構是將光源置於侧 邊’並利用導光板將光線導引向上，再利用光學膜將光線 均勻化並集中’直下式結構不設導光板，直接將光源置於 擴散板下方，而後使光線通過光學膜。 典型光學膜的結構大致上包括擴散膜、增光片等三層相 疊結構’其結構設計目的在使來自光源的入射光線亮度增 加、提供液晶面板亮度、輝度等，對TFT-LCD顯示功效至 ❹ 為重要，因此業界已有許多努力。專利公告第M3 17〇21號、 專利公告M32703 5、M293442等均提供相關技術。 光學膜的成本一直都佔相當的比重；惟為顧及面板亮度 及對比等顯示功效’光學膜仍需使用包括增光片及擴散膜 等多層結構，以確保一定之亮度及輝度。惟因習知光學膜 的擴散層與增光片是分別從兩個生產流程所製成或形成， 而後再予以組合，故背光模組的製造成本仍高，而且常無 法連續製造’大量生產；例如，M293442號專利案是在光 129564.doc 200941089 學基材背面，塗覆具有凹或凸結構之擴散層，即為一例。 因此’有必需提出一種新的技術，使製造流程減化、快速， 而仍能獲得功效佳之光學膜。 【發明内容】 根據以上所述，本發明提供一種製造增亮膜之方法、及 一壓印器，其製造增亮膜之流程較習知技術簡化，而仍具 提高TFT-LCD背光模組亮度、輝度、光折射率、干涉等光 學特性。 ® 【實施方式】 圖1揭露用於製造增亮膜200之壓印系統100之最佳實施 例’用於連續製造出增亮膜200。壓印系統100大致上包括： 彼此相對之一壓印器120、及一擠壓輥輪140。一壓印通道 界定於壓印器120及擠壓輥輪140之間。壓印系統100較佳另 包括一如UV燈180等固化裝置。 圖2顯示壓印器120之局部平面展開後之示意圖，圖3a及 • 3b顯示壓印器120之侧面結構之剖面示意圖及侧面示意 圖，以上各圖顯示其結構細節之示範例。如圖所示，壓印 器120大致上包括一第一結構122，其具有一由凸部123、凹 部124交錯而成之凹凸交錯構形。壓印器120另包括一第二 結構126 ’其形成於該第一結構122之局部表面上。 根據一較佳實施例，壓印器120之本體為金屬材質，表面 為與本體不同之非鐵金屬，如銅、銘、錄（純金屬或其合金） 等；表面之硬度較佳界於180 HV〜650 HV之間。第一結構 122之凹凸交錯構形中，各凸部123之間可為等間距及/或不 129564.doc 200941089 等間距；各凸部123、凹部124之間之深度可為等高及/或不 等高之結構。凸部123、凹部124可以是加工成任何所需形 狀，較佳如圖所示之稜角構形。根據較佳實施例，第一結 構122之凸部123間之間距差較佳為〇〇1〇〜1〇/mm之間，凸部 123與凹部！24間之高度差較佳為〇〇〇1〜〇〇2〇/mm之間。。 壓印器120之第二結構126 ’是壓印器於製作時於第一結 構122之表面上加工所產生，較佳是以珠擊/蝕刻、電鑄、 噴塗等方式於第一結構122之局部表面上加工。珠擊/蝕刻 ❿ 的作用是產生「凹孔陣列」，電鑄及喷塗的作用是產生「凸 粒陣列」。需說明的是，此處「陣列」一詞僅用來表示一個 以上之數目，並非限定排列/分佈方式；因此，「凹孔陣列」 及「凸粒陣列」等詞分別表示「一個以上之凹孔」及「一 個以上之凸粒」。各凹孔或凸粒之顆粒形狀（此處「顆粒」 一詞表示微小之凹孔或凸粒）可以是規則或不規則大小、規 則或不規則形狀、均勻或不均勻分布；顆粒之表面可以是 參光滑或粗糙之表面。第二結構126較佳為不規則形狀但均勻 分佈之顆粒狀結構表面。顆粒尺寸較佳為根據較 么實施例，第二結構126較佳是於凸部j23之頂部形成「凹 孔陣列」，根據此實施例所製成之增亮膜2〇〇具有較佳之功 能’將於後文詳細說明。 根據圖1及圖2’本發明製造增亮膜2〇0之說明如下： (1)提供一壓印系統1〇〇，該壓印系統1〇〇包括彼此相對之 一壓印器120、一擠壓輥輪14〇; 一壓印通道界定於該 麼印器120及該擠壓輥輪ι4〇之間。壓印器ι2〇上具有 129564.doc 200941089 凹凸交錯結構，如前文所述。 (2) 將該壓印器12〇及擠壓輥輪u〇沿一操作方向％旋轉。 (3) 視需要調整該壓印通道之寬度。 (4) 將較佳由一原料捲提供之一光學基材s，沿該操作方 向Μ饋入壓印系統〗00、以使其在壓印器12〇及擠壓輥 輪140壓合下沿該壓印通道前進。藉此，光學基材8在 壓印通道中受擠壓’壓印器120表面之外形轉印在光 學基材S上’使光學基材s表面形成與麼印器12〇上之 ® 凹凸交錯結構互補之凹凸結構。光學基材8較佳為光 學等級南分子塑膠膜。 根據一較佳實施例’在光學基材S饋入壓印系統1 〇〇 前，可視需要於光學基材8上塗布UV膠，以利於後續 之固化步驟。 (5) 俟光學基材S離開壓印通道後，將壓印後之光學基材 固化’以製成一增亮膜200。此一固化步驟一般可以 • UV光源180完成。 圖4及圖5顯示利用本發明之壓印器12〇及以上之步驟所 製成之增亮膜200之照片及結構示意圖。於圖4之照片中， 凹部223及凸部224分別是由壓印器120之凸部123、凹部124 轉印而成’此圖中’第二結構240為分布於凹部223上之凹 孔陣列’該等亮點部位為UV膠填於凹部223上之多個凹孔 後，於固化後於顯微照相中反射光線所形成。可以理解的 是，由於增亮膜200的結構是來自壓印器120轉印而成之一 體成形結構’其凹部223之凹孔陣列其實是由壓印器12〇凸 129564.doc 200941089 部123頂部凸粒陣列於壓印時所形成。在此例中，增亮膜2〇〇 上由凹部223上之凹孔陣列及UV膠複合之結構，可以替代 習知背光模組上的擴散層（擴散片）。較佳的是，習知的背光 模組的擴散層（擴散片）與增光片是分別從兩個生產流程所 製成，而後再予以組合，故背光模組的製造成本較高；但 根據本發明之此一較佳實施例，增亮膜2〇〇可在單一生產流 程上完成，其凹部223上之凹孔陣列&uv膠複合之結構（凹 孔陣列及UV膠複合結構合稱為第二結構），可以替代習知背 光模組上的擴散層，而具凹凸交錯構形的第一結構22〇，仍 具有原有的增光效果。此一組合，使增亮膜2〇〇同時具有習 知增光片及擴散片兩種光學效果，且充分提高亮度、輝度、 光折射率、干涉等現象除了圖4中所示較佳實施例外，增亮 膜200之第二結構240亦可為形成於第一結構22〇上其他部 位之凸粒陣列及/或凹孔陣列，以使增亮膜2〇〇相較於習知 技術具提高亮度、輝度、光折射率、干涉等功效。例如， 若第二結構240為大小尺寸為1 um〜20 um之間均勻分布之 規則或不規則形狀凸粒陣列及/或凹孔陣列，則能加強擴散 及光折射效果’使光的亮度更平均。此外，根據前述壓印 器120之說明，可以瞭解，本發明中增亮膜2〇〇之凹孔陣列 及/或凸粒陣列，可輕易地形成於第—結構22〇之下列部位 至少其中之-：⑴凹部223 ; (2)凸部224 ; (3)除了凹部如 與凸部224外之其他部位。 根據以上所述，本發明利用特殊的壓印器12〇，可生產出 同時具有習知增光片及擴散層之複合效果之增亮膜·，且 129564.doc •9· 200941089 由於增亮膜200上之第一結構22〇及第二結構24〇是於連續 製法中以壓印器120壓印之一體成形結構，相較於習知技 術，成本大大降低》 前述壓印系統100是使用輥輪形式之壓印器120以配合擠 壓輥輪140，是為一最佳實施例，用於連續製造增亮膜2〇〇。 惟可以瞭解的是，亦可將壓印器12〇採平面延伸之結構，並 配合平面延伸結構之擠壓器，雖然不能連續製造而達到最 佳產能，仍可獲得大致相同之增亮膜2〇〇產品。此外，本發 明雖是特別關於增亮膜之技術，惟此一技藝人士根據本案 之揭露亦能明瞭：壓印器12〇亦可用於製造非專指光學膜之 增亮膜。 【圖式簡單說明】 圖1顯示用於製造增亮膜2〇〇之壓印系統1〇〇之一實施例。 圖2顯示壓印器12〇之局部平面展開後之示意圖。 圖3a及3b顯示壓印器i2〇之側面結構之剖面示意圖及側 面示意圖》 圖4顯示本發明製成之增亮膜200之一最佳實施例之顯徵 放大照片。 圖5顯示本製成之增亮膜2〇〇之結構示意圖。 【主要元件符號說明】 100 壓印系統 120 壓印器 122 第一結構 123 凸部 129564.doc 200941089 124 126 140 200 220 223 224 240 ❿ Μ200941089 IX. Description of the Invention: [Technical Field] The present invention discloses a method for manufacturing an optical film, in particular, a method for manufacturing a brightness enhancement film of a TFT_LCD, and a brightness enhancement film produced, and the present invention also discloses A method of manufacturing an optical film/brightness film for use in an imprinter. [Prior Art] TFT-LCD is used for display devices such as notebook computers and liquid crystal televisions, and has a large demand in the market. Since the TFT-LCD cannot emit light by itself, the general © is a backlight module to provide a display light source. The backlight module of the TFT-LCD is divided into two types: the side light type and the direct type: the side light type structure is to place the light source on the side side and guide the light upward by the light guide plate, and then use the optical film to homogenize and concentrate the light. The direct-type structure does not have a light guide plate, and the light source is directly placed under the diffusion plate, and then the light is passed through the optical film. The structure of a typical optical film generally includes a three-layer stacked structure such as a diffusion film and a brightness enhancement sheet. The structure is designed to increase the brightness of the incident light from the light source, provide brightness and brightness of the liquid crystal panel, and display the effect on the TFT-LCD. It is important, so there have been many efforts in the industry. Patent Publication No. M3 17〇21, Patent Announcement M32703 5, M293442, etc. all provide related technologies. The cost of optical films has always been a considerable proportion; however, the display efficiency is considered in consideration of panel brightness and contrast. The optical film still needs to use a multi-layer structure including a brightness enhancement film and a diffusion film to ensure a certain brightness and brightness. However, since the diffusion layer and the brightness enhancement film of the conventional optical film are separately formed or formed from two production processes and then combined, the manufacturing cost of the backlight module is still high, and it is often impossible to continuously manufacture 'mass production; for example, The M293442 patent is a diffusion layer having a concave or convex structure on the back side of the substrate of 129564.doc 200941089, which is an example. Therefore, it is necessary to propose a new technology to make the manufacturing process reduce and fast, and still obtain an optical film with good efficacy. SUMMARY OF THE INVENTION According to the above, the present invention provides a method for manufacturing a brightness enhancement film, and an imprinter, the process of manufacturing the brightness enhancement film is simplified compared to the prior art, and the brightness of the TFT-LCD backlight module is still improved. Optical properties such as luminance, refractive index, and interference. ® [Embodiment] FIG. 1 discloses a preferred embodiment of the imprinting system 100 for manufacturing the brightness enhancing film 200 for continuously producing the brightness enhancing film 200. The embossing system 100 generally includes: one of the stampers 120 opposite each other, and a squeeze roller 140. An embossing channel is defined between the embossing unit 120 and the squeezing roller 140. The embossing system 100 preferably further includes a curing device such as a UV lamp 180. Fig. 2 is a view showing a partial plane of the stamper 120 after unfolding, and Figs. 3a and 3b show a schematic cross-sectional view and a side view of the side structure of the stamper 120, and the above figures show examples of structural details. As shown, the embossing unit 120 generally includes a first structure 122 having a staggered staggered configuration in which the projections 123 and the recesses 124 are interlaced. The stamper 120 further includes a second structure 126' formed on a partial surface of the first structure 122. According to a preferred embodiment, the body of the stamper 120 is made of a metal material, and the surface is a non-ferrous metal different from the body, such as copper, inscription, recording (pure metal or alloy thereof); the hardness of the surface is preferably 180. Between HV and 650 HV. In the staggered and staggered configuration of the first structure 122, the protrusions 123 may be equidistant and/or not equidistant between the 129564.doc 200941089; the depth between each of the protrusions 123 and the recesses 124 may be equal and/or Structures that are not equal in height. The projection 123 and the recess 124 may be machined to any desired shape, preferably as shown in the angular configuration. According to a preferred embodiment, the distance between the projections 123 of the first structure 122 is preferably between 〇〇1〇~1〇/mm, the convex portion 123 and the concave portion! The height difference between the 24 spaces is preferably between 〇〇〇1 and 〇〇2〇/mm. . The second structure 126 ′ of the stamper 120 is formed by processing the stamp on the surface of the first structure 122 during fabrication, preferably by beading/etching, electroforming, spraying, etc. on the first structure 122. Processing on a partial surface. The effect of beading/etching ❿ is to create a “recessed array of holes”. Electroforming and spraying are used to create a “convex array”. It should be noted that the term "array" is used herein to mean more than one number, and is not limited to the arrangement/distribution mode; therefore, the words "recessed hole array" and "convex array" respectively mean "more than one concave Hole" and "more than one bump". The shape of the particles of each recess or embossment (herein the term "particles" means tiny pits or lumps) may be regular or irregular, regular or irregular, uniform or unevenly distributed; the surface of the granule may It is a smooth or rough surface. The second structure 126 is preferably an irregularly shaped but uniformly distributed particulate structure surface. Preferably, the second structure 126 forms a "recessed hole array" on the top of the convex portion j23, and the brightness enhancing film 2 according to this embodiment has a better function. It will be explained in detail later. 1 and 2', the description of the brightness enhancing film 2〇0 of the present invention is as follows: (1) An imprinting system 1 is provided, which includes one of the stampers 120, one opposite to each other. The squeezing roller 14 〇; an embossing passage is defined between the squeegee 120 and the squeezing roller ι4 。. The stamper ι2 has a 129564.doc 200941089 staggered staggered structure as previously described. (2) The stamp 12 〇 and the nip roller u 旋转 are rotated in an operation direction %. (3) Adjust the width of the imprint channel as needed. (4) An optical substrate s, preferably provided by a roll of material, is fed into the embossing system 00 in the direction of operation so that it is pressed down along the embossing device 12 〇 and the squeezing roller 140 The embossing channel advances. Thereby, the optical substrate 8 is pressed in the embossing channel and is transferred onto the optical substrate S outside the surface of the stamper 120, so that the surface of the optical substrate s is formed to be interlaced with the embossing on the embossing device 12 A structure with complementary structures. The optical substrate 8 is preferably an optical grade south molecular plastic film. According to a preferred embodiment, prior to the application of the optical substrate S to the imprinting system 1 , UV glue may be applied to the optical substrate 8 to facilitate subsequent curing steps. (5) After the optical substrate S leaves the embossing channel, the embossed optical substrate is cured to form a brightness enhancing film 200. This curing step can generally be done by the UV light source 180. 4 and 5 are photographs and structures showing the brightness enhancement film 200 produced by the steps of the stamp 12 of the present invention and the above. In the photograph of FIG. 4, the concave portion 223 and the convex portion 224 are respectively transferred by the convex portion 123 and the concave portion 124 of the stamper 120. In this figure, the second structure 240 is an array of concave holes distributed on the concave portion 223. The bright spots are formed by the UV glue filling a plurality of recessed holes in the recess 223, and are formed by reflecting light in a photomicrograph after curing. It can be understood that since the structure of the brightness enhancement film 200 is a one-piece forming structure transferred from the stamper 120, the concave hole array of the concave portion 223 is actually convex by the stamper 12 129564.doc 200941089 part 123 top The array of bumps is formed during embossing. In this example, the brightness enhancement film 2 is formed by a recessed hole array on the concave portion 223 and a UV adhesive composite, which can replace the diffusion layer (diffusion sheet) on the conventional backlight module. Preferably, the diffusion layer (diffusion sheet) and the brightness enhancement sheet of the conventional backlight module are respectively manufactured from two production processes, and then combined, so that the manufacturing cost of the backlight module is high; In a preferred embodiment of the invention, the brightness enhancing film 2 can be completed in a single production process, and the structure of the concave hole array &uv glue composite on the concave portion 223 (the concave hole array and the UV adhesive composite structure are collectively referred to as The second structure) can replace the diffusion layer on the conventional backlight module, and the first structure 22〇 having the concave-convex staggered configuration still has the original brightness enhancement effect. In this combination, the brightness enhancement film 2 〇〇 has both optical effects of the conventional brightness enhancement sheet and the diffusion sheet, and the phenomenon of sufficiently improving brightness, luminance, refractive index, interference, and the like is in addition to the preferred embodiment shown in FIG. 4 . The second structure 240 of the brightness enhancing film 200 may also be an array of convex particles and/or a pattern of recesses formed in other portions of the first structure 22 to improve brightness of the brightness enhancing film 2 compared to conventional techniques. , brightness, refractive index, interference and other effects. For example, if the second structure 240 is a regular or irregularly shaped array of bumps and/or a pattern of concave holes uniformly distributed between 1 um and 20 um in size, the diffusion and light refraction effects can be enhanced to make the brightness of the light more average. In addition, according to the description of the stamper 120, it can be understood that the recessed aperture array and/or the bump array of the brightness enhancing film 2 can be easily formed in at least the following parts of the first structure 22? - (1) concave portion 223; (2) convex portion 224; (3) other portions than the concave portion such as the convex portion 224. According to the above, the present invention utilizes a special stamp 12 〇 to produce a brightness enhancement film having a composite effect of a conventional brightness enhancement sheet and a diffusion layer, and 129564.doc •9· 200941089 due to the brightness enhancement film 200 The first structure 22〇 and the second structure 24〇 are embossed by the stamper 120 in a continuous manufacturing process, and the cost is greatly reduced compared to the prior art. The foregoing imprinting system 100 uses a roller. The stamp embossing 120 of the form to fit the squeezing roller 140 is a preferred embodiment for the continuous manufacture of the brightness enhancing film 2 〇〇. However, it can be understood that the structure of the stamper 12 can be extended and the extruder of the plane extending structure can be used. Although the continuous production can not be achieved to achieve the best production capacity, substantially the same brightness enhancement film can be obtained. 〇〇 product. In addition, although the present invention is particularly directed to the technique of brightness enhancing film, it will be apparent to those skilled in the art from this disclosure that the stamp 12 can also be used to make a brightness enhancing film that is not specifically referred to as an optical film. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 shows an embodiment of an imprinting system 1 for manufacturing a brightness enhancement film. Figure 2 shows a schematic view of the partial plane of the stamp 12 12 after unfolding. Figures 3a and 3b show a schematic cross-sectional view and side views of the side structure of the stamper i2". Figure 4 shows a magnified photograph of a preferred embodiment of a brightness enhancing film 200 made in accordance with the present invention. Fig. 5 is a view showing the structure of the brightness-increasing film 2 of the present invention. [Main component symbol description] 100 Imprinting system 120 Imprinter 122 First structure 123 Projection 129564.doc 200941089 124 126 140 200 220 223 224 240 ❿ Μ
S 凹部 第二結構 擠壓輥輪 增亮膜 第一結構 凹部 凸部 第二結構 操作方向 光學基材S recess second structure squeeze roller brightness enhancement film first structure recess convex portion second structure operation direction optical substrate
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