JP2012242773A - Manufacturing method of pattern phase difference film, and manufacturing method of metal mold for manufacturing pattern phase difference film - Google Patents

Abstract

The present invention relates to a pattern retardation film applied to a three-dimensional image display by a passive method, so that a pattern retardation film can be easily produced in large quantities.
An original plate 21 is prepared by producing an uneven shape corresponding to the uneven shape of a pattern retardation film on a flat plate. A plating film 22 is produced on the surface of the master 21 by electroforming, and the plating film 22 is removed and placed on the surface of the base material 23 to produce the mold 13.
[Selection] Figure 4

Description

  The present invention relates to the manufacture of a pattern retardation film applied to a three-dimensional image display by a passive method.

  Conventionally, flat panel displays have been mainly two-dimensional displays. However, in recent years, flat panel displays capable of three-dimensional display have attracted attention, and some are also commercially available. Further, there is a tendency that future flat panel displays are capable of three-dimensional display, and flat panel displays capable of three-dimensional display are being studied in a wide range of fields.

  In order to perform three-dimensional display on a flat panel display, it is usually necessary to selectively provide a right-eye image and a left-eye image in some manner, respectively, to the viewer's right eye and left eye. As a method for selectively providing a right-eye video and a left-eye video, for example, a passive method is known. This passive three-dimensional display method will be described with reference to the drawings. FIG. 10 is a schematic diagram showing an example of a passive three-dimensional display using a liquid crystal display panel. In the example of FIG. 10, the pixels of the liquid crystal display panel that are continuous in the vertical direction are sequentially assigned to the right eye and the left eye, and are driven by the image data for the right eye and the left eye, respectively. And the image for the left eye are displayed simultaneously. In addition, a pattern retardation film is disposed on the panel surface of the liquid crystal display panel, and light emitted by linearly polarized light from the right-eye and left-eye pixels is converted into circularly polarized light having different directions for the right-eye and left-eye. As a result, in the passive method, glasses equipped with corresponding polarizing filters are attached, and a right eye image and a left eye image are selectively provided to the viewer's right eye and left eye, respectively.

  This passive method can also be applied to a liquid crystal display device having a low response speed, and can also perform three-dimensional display with a simple configuration using a pattern retardation film and circularly polarized glasses. For this reason, a passive liquid crystal display device has attracted a great deal of attention as a center for future three-dimensional display devices.

  By the way, the pattern phase difference film which concerns on a passive system requires the pattern phase difference layer which gives a phase difference to transmitted light corresponding to allocation of a pixel. This pattern retardation film has not been widely researched and developed yet, and there is no established standard technology.

  With respect to this pattern retardation film, Patent Document 1 discloses a production method in which a photo-alignment film in which the alignment regulating force is controlled is formed on a glass substrate, and the alignment of liquid crystals is patterned by this photo-alignment film. However, since the method disclosed in Patent Document 1 requires the use of a glass substrate, there is a problem that the pattern retardation film becomes expensive and it is difficult to mass-produce a large area.

  Regarding the pattern retardation film, Patent Document 2 discloses a photo-alignment film in which a fine uneven shape is formed around a roll plate by laser irradiation, and this uneven shape is transferred to control the alignment regulating force in a pattern shape. A method of making is disclosed. In the method disclosed in Patent Document 2, it is necessary to irradiate the entire circumference of the roll plate with laser without being leaked by laser scanning. Therefore, there is a problem that it takes time to produce the roll plate. There is also a problem that an expensive laser processing apparatus must be used.

JP 2005-49865 A JP 2010-152296 A

  The present invention has been made in view of such a situation, and relates to a pattern retardation film applied to a passive three-dimensional image display. A pattern retardation film capable of easily and in large quantities producing a pattern retardation film. An object of the present invention is to provide a production method of the above, a mold for producing a pattern retardation film and a production method thereof.

  The inventor has conducted extensive research to solve the above-mentioned problems, and formed an uneven shape on the master disk, and arrived at the idea of copying the uneven shape by electroforming to produce a mold. It came to be completed.

    Specifically, the present invention provides the following.

  (1) In the method for producing a patterned retardation film in which the uneven shape formed on the transfer mold is transferred to a transparent sheet material to form an alignment film, the pattern retardation film is formed by patterning the alignment film, A right-eye region that gives a corresponding phase difference to transmitted light for left and a left-eye region that gives a corresponding phase difference to transmitted light for left eye are alternately formed in a band shape, respectively, and the pattern position A method for producing a phase difference film includes a step of producing a master by producing a concavo-convex shape corresponding to the concavo-convex shape of the pattern retardation film on a flat plate, and electroforming the master to obtain a surface of the master An electroforming process for producing a plating film by electroforming, and a method for removing the plating film from the master and placing it on the surface of the base material of the transfer mold to produce the transfer mold. Production of a pattern retardation film comprising: a film treatment step; and a treatment step of a transparent sheet material for producing the pattern retardation film by treating the transparent sheet material using the transfer mold. Method.

  (2) A pattern retardation film production mold for producing an alignment film of a pattern retardation film by transfer to a concavo-convex transparent sheet material formed on the surface, which is formed on a master by electroforming A metal mold for producing a pattern retardation film, wherein a plating film having a concavo-convex shape transferred thereon is disposed on a surface of a base material, and a concavo-convex shape corresponding to the concavo-convex shape of the pattern retardation film is formed.

(3) A method for producing a mold for producing a pattern retardation film in which an alignment film of a pattern retardation film is produced by transfer to a concavo-convex shaped transparent sheet material formed on the surface, wherein the pattern retardation film comprises: By patterning the alignment layer, a right-eye region that gives a corresponding phase difference to the transmitted light for the right eye and a left-eye region that gives a corresponding phase difference to the transmitted light for the left eye are sequentially formed in a band shape, respectively. Alternatingly formed, the method for producing the mold for producing the pattern retardation film is a master production process for producing a master by producing an uneven shape corresponding to the uneven shape of the pattern retardation film on a flat plate, An electroforming process is performed on the master, and a plating film is formed on the surface of the master by electroforming, and the plating film is removed from the master,
And a plating film treatment step of preparing the pattern retardation film preparation mold on the surface of a base material. A method of manufacturing a pattern retardation film preparation mold.

  According to the present invention, it is possible to produce a transfer mold in a short time without using an expensive apparatus when applied to the production of a transfer mold such as a roll plate. Moreover, even if it exists in the original disk by the flat plate required for it, it can produce simply using a highly versatile installation. Therefore, the pattern retardation film applied to the passive three-dimensional image display can be manufactured easily and in large quantities.

It is a figure which shows the pattern phase difference film which concerns on 1st Embodiment of this invention. It is a figure which shows the manufacturing apparatus of the pattern phase difference film of FIG. It is a figure which shows the roll plate in the manufacturing apparatus of FIG. It is a figure where it uses for description of the preparation methods of the roll plate of FIG. It is a figure where it uses for description of the preparation methods of the original disk of FIG. It is a figure which shows the continuation of FIG. It is a figure which shows the continuation of FIG. It is a figure where it uses for description of the manufacturing method of the original disk applied to 2nd Embodiment of this invention. It is a figure which shows the continuation of FIG. It is a figure where it uses for description of the three-dimensional image display by a passive system.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[First Embodiment]
FIG. 1 is a view showing a pattern retardation film according to the first embodiment of the present invention. In the pattern retardation film 1, an alignment film 3 and a retardation layer 4 are sequentially formed on a base material 2 made of a transparent sheet material. In the pattern retardation film 1, the retardation layer 4 is formed of a liquid crystal material, and the alignment of the liquid crystal material is patterned by the alignment regulating force of the alignment film 3. The orientation of the liquid crystal molecules is indicated by a long and narrow ellipse in FIG. By this patterning, the pattern retardation film 1 is formed in a band shape alternately with the right-eye area A and the left-eye area B sequentially with a certain width corresponding to the pixel assignment in the liquid crystal display panel. A phase difference corresponding to each light emitted from the right-eye pixel and the left-eye pixel is given.

  In the pattern retardation film 1, after the ultraviolet curable resin 5 is applied to the surface of the substrate 2, a fine uneven shape is formed on the surface of the ultraviolet curable resin 5, whereby the substrate 2 is interposed via the ultraviolet curable resin. An uneven shape is formed on the surface. In the pattern retardation film 1, the alignment film 3 is formed by the uneven shape on the surface of the ultraviolet curable resin 5. This uneven shape is formed by a streak pattern made up of a number of streaks extending in one direction, and the extending direction of each streak is set to one direction that coincides with the alignment direction of the liquid crystal material in the vicinity of the alignment film 3. Therefore, the uneven shape formed on the surface of the ultraviolet curable resin 5 is such that the extension direction of the stripes is 90 degrees different between the right eye area and the left eye area A and B, and the extension direction of each area. It is formed so as to be inclined by 45 degrees with respect to the angle. In addition, in the inclination with respect to the extension direction of each area | region, when the retardation of the base material 2 is so large that it cannot disregard, it is increased / decreased suitably according to the retardation value.

  FIG. 2 is a schematic diagram showing an apparatus for manufacturing the pattern retardation film 1. In the manufacturing apparatus 10, the base material 2 is provided by a roll, and the base material 2 is supplied from a supply reel 11. The manufacturing apparatus 10 applies an ultraviolet curable resin to the substrate 2 with the die 12. In this manufacturing apparatus 10, the roll plate 13 is a cylindrical mold in which the uneven shape related to the alignment film 3 of the pattern retardation film 1 is formed around. The manufacturing apparatus 10 presses the base material 2 to which the ultraviolet curable resin is applied against the roll plate 13 by the pressure roller 14, and cures the ultraviolet curable resin by irradiation with ultraviolet rays from the ultraviolet irradiation device 15. Thus, the manufacturing apparatus 10 transfers the uneven shape formed on the roll plate 13 to the base material 2. Thereafter, the substrate 2 is peeled from the roll plate 13 by the peeling roller 16, and the liquid crystal material is applied by the die 19. Thereafter, the liquid crystal material is cured by ultraviolet irradiation by the ultraviolet irradiation device 17, and then wound around the take-up reel 18. The pattern retardation film 1 is produced by forming an adhesive layer, an antireflection layer, and the like on the sheet material wound on the take-up reel 18 as necessary, and then cutting it to a desired size. Thereby, in the pattern phase difference film 1, the base material 2 provided by the roll is continuously processed by transferring the concavo-convex shape using the roll plate 13, and is efficiently produced.

  FIG. 3 is a perspective view showing the roll plate 13. In the roll plate 13, ring-shaped regions WA and WB corresponding to the right-eye region A and the left-eye region B of the pattern retardation film 1 are alternately formed in the central axis direction. Corresponding uneven shapes are formed in each of the areas WA and WB.

  FIG. 4 is a diagram for explaining the manufacturing process of the roll plate 13. In this step, the master 21 is first prepared. Here, the master disk 21 (FIG. 4A) is a flat plate having a concavo-convex shape corresponding to each area WA, WB of the roll plate 13 formed on the surface. In this step, the master 21 is electroformed to produce a nickel plated film 22 (FIG. 4B). Subsequently, the plating film 22 is peeled off and attached to the base material 23 of the roll plate 13 (FIG. 4C). Here, the base material 23 is formed by forming a protective film such as a nickel film on a cylindrical base material made of copper with the periphery polished. In this step, a plating film 22 is produced with a length that goes around the side surface of the base material 23. After the plating film 22 is wound around the side surface of the base material 23, the plating film 22 is applied to the base material 23 by a laser. The roll plate 13 is produced by welding. A roll plate is produced in a short time with a simple configuration by arranging the electroformed film produced by electroforming the master plate 21 using a flat plate on a cylindrical base material to produce a roll plate. It is possible to produce a pattern retardation film easily and in large quantities using this roll plate. Note that various methods such as adhesion using a thermosetting resin can be widely applied to the arrangement of the plating film 22 on the base material 23.

  FIG. 5 is a diagram illustrating a manufacturing process of the master 21. In this master production process, a resin layer 26 for rubbing treatment is produced on the surface of the substrate 25 having a smooth surface (FIG. 5A). For example, a glass substrate is applied to the substrate 25, and a polyimide resin is applied to the resin layer 26. However, various materials can be applied as necessary.

  Subsequently, in this master production process, a resist layer 27 is formed on the surface of the resin layer 26 (FIG. 5B), and a region corresponding to the region A for the right eye or the region B for the left eye provided on the pattern retardation film 1. The resist layer 27 is exposed to light using a mask 28 provided with a light shielding portion (FIG. 5C). Note that exposure processing may be performed by scanning with a laser beam instead of exposure processing using a mask.

  Subsequently, in this master disc production process, development and cleaning processes are performed, and the rubbing process in which the resist layer 27 is selectively left in the region corresponding to the left-eye region B or the right-eye region A of the pattern retardation film 1. A processing mask is manufactured (FIG. 5D). Note that a negative resist may be used in place of the positive resist that removes the unexposed portion. Subsequently, as shown in FIG. 6, this process is performed by rubbing with a roll R for rubbing treatment, and corresponding irregularities corresponding to the region corresponding to the region A for the right eye or the region B for the left eye of the pattern retardation film 1. A shape is produced (FIG. 6E). Subsequently, the resist layer 27 is removed (FIG. 6F).

  Subsequently, a resist layer 29 is formed on the entire surface (FIG. 6G), and a mask in which a light shielding portion is provided in a region corresponding to the region A for the right eye or the region B for the left eye of the pattern retardation film 1. 30 is used to expose the resist layer 29 (FIG. 6H). In this case, the exposure process may be performed by scanning with a laser beam instead of the exposure process using a mask.

  Subsequently, in this master production process, development and cleaning processes are executed, and as shown in FIG. 7, the pattern retardation film 1 is selectively applied to a region corresponding to the region A for the right eye or the region B for the left eye. A rubbing mask that leaves the resist layer 29 is produced (FIG. 7I). In this case, a negative resist may be used instead of the positive resist. Subsequently, in this step, a rubbing process is performed with a roll R for rubbing process, and a corresponding uneven shape is produced in a region corresponding to the left eye region B or the right eye region A of the pattern retardation film 1 (FIG. 7). (J)). Subsequently, the resist layer 29 is removed (FIG. 7 (k)), and the master 21 is completed.

  In this embodiment, the concavo-convex shape of the master is transferred to a plating film by electroforming, and a roll plate is produced by using the plating film, thereby forming a concavo-convex shape directly on the base material to produce a roll plate. Compared with the case where it does, a roll plate can be produced by a remarkably simple structure, and a pattern retardation film can be produced by the continuous process using this roll plate. Therefore, it is possible to produce a pattern retardation film easily and in a large amount as compared with the prior art.

[Second Embodiment]
In this embodiment, instead of the master 21 described above with reference to FIG. 5, a roll plate is produced using the master 34 produced by the production steps of FIGS. The second embodiment is configured in the same manner as the first embodiment except that the master is different.

  Here, in this master production process, a resin layer 26 for rubbing treatment is produced on the surface of the substrate 25 having a smooth surface (FIG. 8A). For example, a glass substrate is applied to the substrate 25, and a polyimide resin is applied to the resin layer 26. However, various materials can be applied as necessary. Subsequently, in this master production process, the entire surface is rubbed with a roll R for rubbing treatment, and a concavo-convex shape corresponding to the area A for the right eye or the area B for the left eye of the pattern retardation film 1 is produced on the entire surface (FIG. 8 (b)).

  Subsequently, after a resist layer 27 is formed on the entire surface (FIG. 8C), a mask 28 in which a light shielding portion is provided in a region corresponding to the right-eye region A or the left-eye region B of the pattern retardation film 1. Is used to expose the resist layer 27 (FIG. 8D). In this case, the exposure process may be performed by scanning with a laser beam instead of the exposure process using a mask.

  Subsequently, in this master production process, development and cleaning processes are executed, and as shown in FIG. 9, a pattern phase difference film 1 is selectively applied to an area corresponding to the area A for the right eye or the area B for the left eye. A rubbing mask that leaves the resist layer 27 is produced (FIG. 9E). In this case, a negative resist may be used instead of the positive resist. Subsequently, in this step, a rubbing process is performed with a roll R for rubbing process, and a corresponding uneven shape is produced in a region corresponding to the left-eye region B or the right-eye region A of the pattern retardation film 1 (FIG. 9). (F)). In this case, the uneven shape produced by the first rubbing process in the region is removed by the second rubbing process, and only the uneven shape by the second rubbing process remains in the region. .

  In this step, the resist layer 27 is subsequently removed (FIG. 9G), whereby the master 34 is completed.

  In this embodiment, even when the master is produced by another manufacturing method, the same effect as that of the first embodiment can be obtained. Further, in this embodiment, after the entire surface is rubbed, the master can be manufactured in a simpler process compared to the first embodiment by locally changing the uneven shape by mask rubbing to prepare the master. it can. Therefore, a patterned retardation film can be produced with a simpler structure as a whole.

[Other Embodiments]
The specific configuration suitable for the implementation of the present invention has been described in detail above, but the present invention can be variously modified and further combined with the configuration of the above-described embodiment without departing from the spirit of the present invention. .

  That is, in the above-described embodiment, the case of producing a fine uneven shape having an alignment regulating force by rubbing treatment has been described, but the present invention is not limited to this, and this kind of uneven shape is obtained by polishing with a fine file. Various methods can be widely applied in the case of manufacturing.

  Further, in the above-described embodiment, the case where the electroplating process is performed directly on the master plate using the flat plate to produce the plating film is described. However, the present invention is not limited to this, and the master plate may be obtained by transferring the uneven shape from the flat plate described above. good. In this case, a master disk is produced from a large number of copies from the original master disk, and roll plates are respectively manufactured. Thus, the pattern retardation film can be further mass-produced. Moreover, it is also possible to use the sheet material which produced the uneven | corrugated shape on the base material using the other roll plate as a master, and in this case, the roll plate can be easily duplicated.

  Further, in the above-described embodiment, the case has been described in which the uneven shape region related to the right eye region and the uneven shape region related to the left eye region are sequentially formed on the outer periphery of the roll plate in a ring shape. However, the present invention is not limited to this, and can be widely applied to the case where each uneven region is formed so as to extend in the axial direction which is a direction orthogonal to the above.

  In the above-described embodiment, the case where the roll plate is manufactured by arranging the plating film on the cylindrical base material has been described. However, the present invention is not limited thereto, and the base material is manufactured by a columnar shape as a roll plate. Alternatively, a flat plate mold may be manufactured by arranging a plating film on a flat plate base material.

  In the above-described embodiment, the case where a pattern retardation film is prepared on the premise of using a liquid crystal display panel is described, but the present invention is not limited to this, and on the premise of using an organic EL panel or a plasma display panel. The present invention can be widely applied also when the polarizing filter is provided integrally.

DESCRIPTION OF SYMBOLS 1 Pattern phase difference film 2 Base material 3 Orientation film 4 Phase difference layer 5 UV curable resin 10 Manufacturing apparatus 11 Supply reel 12, 19 Die 13 Roll plate 14 Pressure roller 15, 17 Ultraviolet irradiation apparatus 16 Peeling roller 18 Take-up reel 21 , 34 Master 22 Plated film 23 Base material 25 Substrate 26 Resin layer 27, 29 Resist layer 28, 30 Mask R Roll

Claims (3)

In the method for producing a pattern phase difference film in which an uneven film formed on a transfer mold is transferred to a transparent sheet material to form an alignment film.
The pattern retardation film is
By patterning the alignment layer, a right-eye region that gives a corresponding phase difference to the transmitted light for the right eye and a left-eye region that gives a corresponding phase difference to the transmitted light for the left eye are sequentially formed in a band shape, respectively. Alternately formed
The method for producing the pattern retardation film is as follows.
On the flat plate, a master disc production step for producing a master plate by producing a concavo-convex shape corresponding to the concavo-convex shape of the pattern retardation film,
An electroforming process for electroplating the master and producing a plating film by electroforming on the surface of the master;
A plating film processing step of removing the plating film from the master and placing the transfer film on a surface of a base material related to the transfer mold to produce the transfer mold;
A process for producing a pattern phase difference film, comprising: using the transfer mold, and processing the transparent sheet material to produce the pattern phase difference film. A mold for producing a pattern retardation film for producing an alignment film of a pattern retardation film by transferring to a concavo-convex shaped transparent sheet material formed on the surface,
A plating film formed by transferring an uneven shape formed on the master by electroforming is disposed on the surface of the base material, and an uneven shape corresponding to the uneven shape of the pattern retardation film is formed. Mold for retardation film production. A method for producing a mold for producing a pattern retardation film, which produces an alignment film of a pattern retardation film by transferring to a concavo-convex shaped transparent sheet material formed on the surface,
The pattern retardation film is
By patterning the alignment layer, a right-eye region that gives a corresponding phase difference to the transmitted light for the right eye and a left-eye region that gives a corresponding phase difference to the transmitted light for the left eye are sequentially formed in a band shape, respectively. Alternately formed
The method for producing the mold for producing the pattern retardation film is as follows.
On the flat plate, a master disc production step for producing a master plate by producing a concavo-convex shape corresponding to the concavo-convex shape of the pattern retardation film,
An electroforming process for electroplating the master and producing a plating film by electroforming on the surface of the master;
A plating film processing step of removing the plating film from the master and disposing the plating film on a surface of a base material to prepare the mold for preparing the pattern retardation film. Manufacturing method.

Images