JP2016110079A - Polarizer, manufacturing method of polarizer, and liquid crystal display device and image display device - Google Patents

Abstract

[PROBLEMS] To improve mass productivity, wear resistance, and manufacturing accuracy of wire grid polarizers as compared with conventional ones. A polarizer 4 for limiting the transmission of incident electromagnetic waves according to the plane of polarization includes a polarizing layer 13 having an optical function as the polarizer 4, and the polarizing layer 13 has a wavelength band for limiting transmission. A plurality of metal linear portions 11 made of a metal material with a line width equal to or shorter than the shortest wavelength are arranged apart from each other in the direction of the line width, and between adjacent metal linear portions 11 against electromagnetic waves in the wavelength band. A transparent solid dielectric portion 12 made of a transparent solid dielectric is provided. An end face of the metal linear part 11 in the thickness direction protrudes 20 nm or more from an end face of the adjacent transparent solid dielectric part 12. [Selection] Figure 2

Description

  The present invention relates to a wire grid polarizer.

  Conventionally, in image display devices and the like, various configurations using a polarizer have been proposed. That is, for example, in a liquid crystal display device, a liquid crystal cell is formed by sandwiching a liquid crystal material with a glass plate on which a transparent electrode is arranged, and a linear polarizing plate is arranged on both sides of the liquid crystal cell to constitute a liquid crystal display panel. In recent years, a device has been devised in which a reflective linear polarizing plate is arranged on the incident surface (backlight side surface) of the liquid crystal display panel to improve the use efficiency of illumination light by the backlight.

  In addition, the image display device has been devised to prevent reflection of extraneous light by arranging a circularly polarizing plate formed by laminating a linearly polarizing plate and a quarter-wave plate on the panel surface of the image display panel.

  As such a polarizer, a configuration (so-called sheet polarizer), a wire grid type polarizer, and the like, which are made by impregnating polyvinyl alcohol (PVA) with iodine or the like and then stretching, are used. Patent Documents 1 and 2 propose a device relating to a wire grid polarizer.

  In such a polarizer, the sheet polarizer has inferior heat resistance and further disadvantages that it is difficult to reduce the thickness. Accordingly, it is conceivable to use a wire grid type polarizer instead of the sheet polarizer. However, the wire grid type polarizer has a problem that mass productivity, wear resistance, and production accuracy are inferior because it is necessary to produce a fine and complicated uneven shape.

JP 2006-330521 A JP 2012-27221 A

  The present invention has been made in view of such a situation, and an object of the present invention is to improve the mass productivity, wear resistance, and production accuracy of a wire grid polarizer as compared with the related art.

  The present inventor has intensively studied to solve the above-mentioned problems, and has arrived at the idea that a transparent solid dielectric part made of a transparent solid dielectric is provided between adjacent metal linear parts. It came to be completed.

    Specifically, the present invention provides the following.

(1) In a polarizer that limits the transmission of incident electromagnetic waves according to the plane of polarization,
Provided with a polarizing layer responsible for the optical function as a polarizer,
The polarizing layer is
A plurality of metal linear portions made of a metal material with a line width equal to or less than the shortest wavelength of a wavelength band that restricts transmission are arranged apart in the direction of the line width,
A transparent solid dielectric portion made of a solid dielectric transparent to the electromagnetic wave in the wavelength band is provided between the adjacent metal linear portions,
The polarizer which the end surface of the said metal linear part which concerns on the thickness direction protrudes 20 nm or more from the end surface of the said adjacent transparent solid dielectric part.

  According to (1), since the transparent solid dielectric part by the transparent solid dielectric is provided between the adjacent metal linear parts, the damage of the metal linear parts is reduced as compared with the prior art. Thus, the wear resistance can be improved as compared with the conventional case. In addition, the configuration in which the transparent solid dielectric portion is provided between the adjacent metal linear portions as described above is produced by forming a concave / convex shape by a concave groove corresponding to the metal linear portion, and then relating the metal linear portion to the concave groove. It can be manufactured by filling a material, whereby a large-area polarizer can be efficiently produced, and mass productivity can be improved as compared with the conventional case. Moreover, by being able to be manufactured in this way, the manufacturing accuracy of the metal linear portion can be improved, and as a result, the manufacturing accuracy can also be improved. Furthermore, the end face of the metal linear part in the thickness direction protrudes 20 nm or more from the end face of the adjacent transparent solid dielectric part, thereby reducing the thickness of the metal linear part compared to the transparent solid dielectric part. The thickness can be increased, and as a result, the extinction ratio can be increased to improve the characteristics.

(2) The polarizer according to (1), wherein a cross-sectional shape of the end surface in the width direction of the metal linear portion is a curved shape protruding from the center.
According to (2), the mass productivity, the wear resistance, and the production accuracy can be improved by a more specific configuration as compared with the conventional case.

  (3) The polarizer according to (1) or (2), wherein a metal film made of the material of the metal linear portion is provided on an end surface of the transparent solid dielectric portion.

  According to (3), in the configuration in which the metal film made of the material of the metal linear part exists or remains on the end surface of the transparent solid dielectric part, the mass productivity, the wear resistance, and the production accuracy are improved as compared with the conventional case. can do.

(4) In any one of (1), (2) and (3),
A polarizer in which a transparent layer that is transparent to electromagnetic waves in the wavelength band is provided on at least one surface of the polarizing layer.

  According to (4), the polarizer can be configured with a more specific configuration by applying a layer configuration for preparing a polarizing layer, a protective layer for the polarizing layer, and the like to the transparent layer.

(5) In (4),
The polarizer whose said transparent layer is a protective layer of the said polarizing layer.

  According to (5), the polarizer can be configured with a more specific configuration by applying the protective layer of the polarizer to the transparent layer.

  (6) The polarizer according to (4), wherein the transparent layer is a transparent resin layer integral with the transparent solid dielectric portion.

  According to (6), the polarizer can be configured with a more specific configuration by applying to a layer configuration in which the polarizing layer is transferred by, for example, a transfer method.

  (7) In (4), the transparent layer is a transparent resin layer integral with the transparent solid dielectric portion, and a polarizer which is a base material of the transparent resin layer

  According to (7), the transparent layer can be applied to a layer structure for producing a polarizing layer to form a polarizer with a more specific structure.

  (8) In any one of (1), (2), (3), (4), (5), (6), (7), the metal material of the metal linear portion is aluminum, nickel, chromium A polarizer containing any of silver and silver.

  According to (8), it is possible to provide a polarizer that can efficiently reflect or absorb incident light on a specific polarization plane.

(9) In a method for manufacturing a polarizer that restricts transmission of incident electromagnetic waves according to a polarization plane,
Concavities and convexities that produce a concave-convex shape formed by arranging a plurality of concave grooves with a groove width equal to or shorter than the shortest wavelength of the wavelength band on a base material transparent to electromagnetic waves in a wavelength band that restricts transmission. Shape production process;
Metal forming a metal layer on the surface on which the concave groove is formed, thereby disposing a metal material in the concave groove to form a linear metal linear portion with a line width equal to or shorter than the shortest wavelength A linear part manufacturing process,
A method for producing a polarizer, wherein at least the metal layer between the adjacent concave grooves is removed, and an end surface of the metal linear portion in the thickness direction protrudes 20 nm or more from an end surface of a member related to the adjacent concave groove.

  According to (9), since the member which concerns on a concave groove can be provided between adjacent metal linear parts, the damage of a metal linear part can be reduced compared with the past, and, thereby, conventionally As compared with the above, the wear resistance can be improved. In addition, after producing a concave-convex shape corresponding to the metal linear portion, the concave groove can be filled with a material related to the metal linear portion, thereby producing a large area polarizer efficiently. It is also possible to improve the mass productivity as compared with the prior art. Moreover, by being able to be manufactured in this way, the manufacturing accuracy of the metal linear portion can be improved, and as a result, the manufacturing accuracy can also be improved. Furthermore, the end face of the metal linear portion in the thickness direction is projected by 20 nm or more from the end face of the member related to the adjacent concave groove, thereby increasing the thickness of the metal linear portion as compared with the transparent solid dielectric portion. As a result, the extinction ratio can be increased and the characteristics can be improved.

(10) In (9),
The uneven shape manufacturing step includes
The manufacturing method of the polarizer which produces the said uneven | corrugated shape in the said base material by the shaping process which uses the metal mold | die for shaping.

  According to (10), it is possible to efficiently produce a concavo-convex shape by a shaping process, further improving mass productivity and improving production accuracy.

(11) In (9) or (10),
The metal linear part production process includes:
A method for producing a polarizer, wherein the metal layer is produced by any one of vapor deposition, sputtering, electroplating, electroless plating, chemical vapor deposition, atomic layer deposition, oxidation-reduction reaction, and nanoparticle deposition.

  According to (11), with a more specific configuration, it is possible to manufacture a polarizer while ensuring mass productivity, wear resistance, and production accuracy as compared with the conventional case.

  (12) The polarizer according to any one of (1), (2), (3), (4), (6), (7), and (8) is provided on the exit surface side and / or the entrance surface of the liquid crystal cell. Liquid crystal display device arranged on the side.

  According to (12), the liquid crystal display device is applied to a linearly polarizing plate disposed on the incident / exiting surface of the liquid crystal cell and a reflective linearly polarizing plate disposed on the backlight side of the incident surface side linearly polarizing plate of the liquid crystal cell. Can be configured.

  (13) The polarizer according to any one of (1), (2), (3), (4), (6), (7), and (8) is an incident surface side linearly polarizing plate of a liquid crystal display panel. Liquid crystal display device that is integrated with the display.

  According to (13), it is applied to a reflective linear polarizing plate disposed on the backlight side of the incident surface side linear polarizing plate of the liquid crystal cell, and is integrated with the incident side linear polarizing plate so as to be polarized. The work related to the arrangement of the child can be simplified.

  (14) The polarizer according to any one of (1), (2), (3), (4), (6), (7), and (8) is disposed on the panel surface of the image display panel. Image display device.

  According to (14), the image display device can be configured by applying to an antireflection film or the like laminated with a quarter wavelength plate.

(15) In any one of (1), (2), (3), (4), (5), (6), 7), (8),
The metal linear part is:
A polarizer comprising a reflection suppressing layer for suppressing reflection of incident light on an end surface protruding from an end surface of the transparent solid dielectric portion.

  According to (15), it is possible to expand the field of application of this type of polarizer by suppressing reflection by the metal linear part on one side.

(16) In any one of (1), (2), (3), (4), (5), (6), (7), (8), (15),
A polarizer in which an intermediate layer for enhancing adhesion is provided between the transparent solid dielectric portion and the metal linear portion.

  According to (16), when producing a metal linear part in a transparent solid dielectric part by a concave groove, the metal linear part can be provided with high reliability by strengthening the adhesion, and as a result, reliability Can be improved.

(17) In any one of (9), (10), and (11),
The metal linear part production process includes:
The manufacturing method of a polarizer provided with the process of producing the reflection suppression layer which suppresses reflection of incident light in the edge part of the said metal linear part formed in the said concave groove.

  According to (17), the application field of this kind of polarizer can be expanded by suppressing reflection by the metal linear part on one side.

  (18) The polarizer according to any one of (15) and (16) is disposed on the side surface of the backlight of the liquid crystal cell while the surface on which the antireflection layer is produced is held on the side surface of the liquid crystal cell. Liquid crystal display device.

  According to (18), by arranging the side on which the antireflection layer is formed as the liquid crystal cell side on the backlight side, the light emitted from the backlight is used effectively, and the reflection by the extraneous light is sufficient. Can be suppressed.

  According to the present invention, mass productivity, wear resistance, and production accuracy can be improved with respect to the wire grid type polarizer as compared with the related art.

It is sectional drawing which shows the image display apparatus which concerns on 1st Embodiment of this invention. It is a figure which shows the structure of the polarizer which concerns on the image display apparatus of FIG. It is a figure which shows the cross-sectional shape of a polarizing layer. It is a flowchart which shows the manufacturing process of a polarizer. It is a figure where it uses for description of each process of FIG. It is a figure where it uses for description of a roll version. It is a figure where it uses for description of the manufacturing method of the roll plate which concerns on 2nd Embodiment of this invention. It is a figure which shows the polarizer applied to the image display apparatus which concerns on 4th Embodiment of invention. It is a figure which shows the polarizer applied to the image display apparatus which concerns on 5th Embodiment of invention.

[First Embodiment]
(Image display device)
FIG. 1 is a sectional view showing an image display apparatus according to the first embodiment of the present invention. The image display device 1 is a liquid crystal display device, and a backlight 3 is disposed on the back surface of the liquid crystal display panel 2, and a polarizer 4 is disposed on the backlight 3 side of the liquid crystal display panel 2. Here, as the backlight 3, various surface light source devices such as an edge light type and a direct light type can be widely applied. The liquid crystal display panel 2 is configured by sandwiching a liquid crystal cell 5 by linearly polarizing plates 6 and 7 having a crossed Nicol arrangement or a parallel Nicol arrangement, and the liquid crystal cell 5 sandwiches a liquid crystal material by a glass substrate on which a transparent electrode is formed. It is formed. As a result, the image display device 1 modulates the intensity of the transmitted light in units of pixels by the voltage applied to the transparent electrode provided in the liquid crystal cell 5 and outputs it, thereby displaying a desired image.

  The polarizer 4 is a wire grid polarizer, and is a so-called reflective polarizer that selectively and efficiently reflects incident light from a polarization plane orthogonal to the transmission axis direction. The polarizer 4 is arranged so that the transmission axis direction of the linearly polarizing plate 7 arranged on the incident surface side (backlight 3 side) of the liquid crystal cell 5 coincides with the transmission axis direction. The use efficiency of the illumination light from the backlight 3 is improved. In this embodiment, the polarizer 4 is integrated with the linearly polarizing plate 7 in advance, and then provided to the manufacturing process of the liquid crystal display panel 2, whereby the image display device 1 is assembled by the polarizer 4. Can be simplified.

  This integration is performed by bonding the polarizer 4 and the linearly polarizing plate 7 together with an adhesive such as an ultraviolet curable resin, but only the polarizing layer, which is a layer responsible for the optical function as the polarizer, is transferred. It may be transferred and executed by the method. The transfer method refers to, for example, when a desired layer is formed on a base material, the layer is not directly formed on the base material, but can be peeled once on a releasable support. After forming the transfer body by laminating the layers, the layer formed on the support is finally placed on the substrate (transfer base material) on which the layer is to be laminated according to the process, demand, etc. In this method, a desired layer is formed on the substrate by bonding and laminating, and then peeling and removing the support. Regarding the arrangement of the polarizing layer by this transfer method, in this embodiment, the polarizing layer is integrally formed with a transparent resin layer by a shaping resin layer described later.

  Further, the polarizer 4 may be disposed on the incident surface of the liquid crystal cell 5 in place of the linear polarizer 7 so as to omit the linear polarizer 7. Further, instead of the linearly polarizing plate 6, it may be arranged on the exit surface of the liquid crystal cell 5. In this case, in the case where the polarizer is disposed on the exit surface side of the liquid crystal cell in place of the linear polarizing plate 6, a so-called absorption type that efficiently absorbs incident light from a polarization plane orthogonal to the transmission axis direction is configured. Is desirable.

[Polarizer]
FIG. 2 is a diagram showing the configuration of the polarizer 4. The polarizer 4 is a polarizer that restricts the transmission of incident light, which is an incident electromagnetic wave, according to the polarization plane, and is provided with a polarizing layer 13 that has an optical function as a polarizer. In the polarizer 4, a plurality of metal linear portions 11 are arranged in the polarizing layer 13 so as to be separated in the line width direction. Here, the metal linear portion 11 is formed of a metal material with a line width Wm that is equal to or shorter than the shortest wavelength λmin of the wavelength band of the electromagnetic wave that restricts transmission. Further, the metal linear portions 11 are repeatedly arranged regularly or irregularly at a pitch P of the shortest wavelength λmin or less. As a result, the interval Wt between adjacent metal linear portions 11 (the width of a transparent solid dielectric portion 12 described later) has a duty ratio D (= Wm / P = Wm / (Wm + Wt)) of 0.2 or more. It is made to be 0.8 or less, preferably 0.3 or more and 0.7 or less. Since the surface of the polarizing layer 13 may have a curved surface shape, the line width Wm is defined by a width viewed from a direction orthogonal to the extending direction of the linear portion 11 and the repeating direction of the metal linear portion 11. Is done. Note that the shortest wavelength λmin is applied to the image display device as in this embodiment, and when the transmission is limited with respect to the entire wavelength band of the visible light region, the shortest wavelength of 380 nm or less, for example, described later For example, in the case of limiting the transmission of ultraviolet rays used for exposure by applying to an exposure apparatus using ultraviolet rays, a wavelength different from 380 nm is appropriately applied.

  The metal linear portion 11 is formed so that the thickness H is equal to or less than λmin with respect to the shortest wavelength λmin. In this embodiment, the metal linear portion 11 is formed in a substantially rectangular shape in cross section. Accordingly, the polarizer 4 is configured to function as a wire grid polarizer. In the polarizer 4, for example, in the wavelength band of the visible light region, a plurality of wavelengths such as the shortest wavelength 380 nm, the center wavelength 550 nm, and the longest wavelength 780 nm are set as design reference wavelengths, and desired optical characteristics (for example, at these design reference wavelengths) P wave transmittance corresponding to pitch P, line width Wm, thickness H by simulation based on the refractive index n and attenuation coefficient k of the metal material and the transparent dielectric material so that the extinction ratio) can be secured. By calculating the S wave transmittance and the extinction ratio, suitable values for the necessary pitch P, line width Wm, and thickness H are derived. Thus, for example, when a sufficient extinction ratio is secured at a wavelength of 550 nm, pitch is used when aluminum is used for the metal layer and a general ultraviolet curable resin (n = 1.5, k = 0 at 550 nm) is used for the transparent dielectric. P is 75 nm to 175 nm, preferably 100 nm to 150 nm. The thickness is 90 nm to 200 nm, preferably 110 nm to 160 nm, and more preferably 120 nm to 150 nm.

Further, the polarizing layer 13 is provided with a transparent solid dielectric portion 12 made of a solid dielectric transparent to an electromagnetic wave in a wavelength band for limiting transmission between adjacent metal linear portions 11. Thus, by providing the transparent solid dielectric part 12 between the adjacent metal linear parts 11, the polarizer 4 can reduce the damage of the metal linear part 11 by the contact of various members, etc. As compared with the above, the wear resistance can be improved. In addition, in the configuration in which the transparent solid dielectric portion 12 is provided between the adjacent metal linear portions 11 in this way, after forming an uneven shape by a concave groove corresponding to the metal linear portion 11, a metal wire is formed in the concave groove. Thus, it is possible to produce a large-area polarizer efficiently, and to improve mass productivity as compared with the related art. Moreover, by being able to be manufactured in this way, the manufacturing accuracy of the metal linear portion 11 can be improved, and as a result, the manufacturing accuracy as the polarizer 4 can also be improved. Moreover, when producing the metal linear part 11 by filling, you may provide the functional layer for adhesiveness or surface protection on a concave groove as needed. Although the functional layer is not limited in particular, it is mainly Si or a compound _thereof, SiO 2, SiC, etc. are preferable.

  Here, as shown in the cross-sectional shape in the line width direction in FIG. 3, one end surface of the metal linear portion 11 may be a flat surface (FIG. 3A), and the central portion in the line width direction. May be produced with a curved surface shape protruding (FIG. 3B), or may be produced with a curved surface shape opposite to this. Further, as shown in FIG. 3C, the adjacent metal wire portions 11 are connected by the material of the metal wire portions 11, and the thickness d of the connected portions is a wavelength band for limiting transmission. In this case, the adjacent metal wire portions 11 may be connected entirely or partially by the material of the metal wire portions 11. Thus, when connecting the adjacent metal linear part 11 with the material of this metal linear part 11, the process process regarding the metal linear part 11 in the manufacturing process of the polarizer 4 mentioned later can be simplified.

  However, in this embodiment, even if the end surface shape of the metal linear portion 11 is thus various shapes, the end surface of the metal linear portion 11 in the thickness direction is adjacent to the transparent solid dielectric portion 12. It is created so that it protrudes 20 nm or more from the end face of. The protrusion amount Δd is defined by the distance between the central portion of the linear metal part 11 in the line width direction and the central part in the width direction of the adjacent transparent solid dielectric part 12. The protrusion amount Δd is obtained from an average value of a plurality of samplings measured according to this definition. More specifically, in the polarizing layer 13, the metal linear part 11 is formed by producing a concave groove corresponding to the metal linear part 11 and arranging the metal material, and the transparent member between adjacent concave grooves is transparent. The solid dielectric portion 12 is configured. In the example of FIG. 3, the protrusion amount Δd in the thickness direction is a polarizing layer between the central portion of the concave groove root side end surface of the transparent member related to the concave groove and the central portion of the end surface of the adjacent metal linear portion 11. It is calculated | required by the difference of the height which concerns on 13 thickness directions. By projecting the metal linear part 11 in this way, the metal linear part 11 can be made thicker than the transparent solid dielectric part, and as a result, the polarizer 4 increases the extinction ratio. Thus, the characteristics can be improved. The extinction ratio is such that the incident light by linearly polarized light is incident, the transmittance Tmax when the polarization plane of the incident light is the transmission axis direction, and the polarization plane of the incident light is the absorption axis direction. It is a ratio to the transmittance Tmin.

  Here, as the metal material related to the metal linear portion 11, for example, metals, alloys, metal compounds, and the like related to various conductors can be widely applied. However, any of these metals such as aluminum, nickel, chromium, and silver, whichever It is desirable to apply alloys of these metals and compounds of these metals. From the viewpoint of efficiently reflecting electromagnetic waves that limit transmission, it is desirable to apply metals, alloys, and compounds having high reflectivity such as aluminum, nickel, and silver, and aluminum is particularly suitable for visible light. preferable. On the other hand, from the viewpoint of suppressing the reflection of electromagnetic waves that limit transmission, it is desirable to apply a metal, alloy, or compound having a low reflectance such as chromium.

  The metal linear portion 11 may be formed by a plurality of layer structures. By producing with such a layer structure, for example, the characteristics can be made different from incident light incident from both surfaces of the polarizing layer 13, and the hues of both surfaces of the polarizing layer 13 can be made different.

  In the polarizer 4 (FIG. 2), a molding resin layer 16 is provided on a base material 15 made of a transparent film material, and a fine concavo-convex shape is produced by molding processing of the molding resin layer 16 so that a transparent solid dielectric portion is formed. 12 is produced. In addition, a metal layer is formed on the surface on which the fine concavo-convex shape is formed by vapor deposition, sputtering, electric field plating, electroless plating, or the like, and the metal linear portion 11 is manufactured. The polarizer 4 is formed on the transparent solid dielectric portion 12 by a process such as etching, cutting, polishing, etc. according to the shape of the upper end surface of the metal linear portion 11 (FIGS. 3A to 3C) desired. The metal layer on the end surface of the transparent solid dielectric portion 12 between the metal linear portions is removed so that the end surface is exposed.

  In the production of the metal linear portion 11, chemical vapor deposition, atomic layer deposition, oxidation-reduction reaction, nanoparticle deposition, or the like can be applied. Here, the oxidation-reduction reaction method means a metal layer preparation method in which a metal layer is prepared by reducing an oxidized metal material with a reducing agent, and is, for example, a metal layer preparation method represented by a silver mirror reaction. Here, the reducing agent may be included in the transparent solid dielectric portion forming the uneven shape. In addition, the nanoparticle deposition method is a method in which a metal layer is produced by depositing nanoparticles such as aluminum on a concavo-convex surface, or a method in which a metal linear portion is produced by selectively depositing in a concave groove. Yes, if necessary, after depositing the nanoparticles, a step such as firing is provided to fix the deposited nanoparticles to the concave groove.

  Although various transparent members can be applied to the base material 15 as the polarizer 4, a film material having a small optical anisotropy is preferable. In this embodiment, COP (cycloolefin polymer) or TAC (triacetylcellulose) is used. ) Film is applied. However, when a wet process such as etching is applied in the manufacturing process, the TAC film is not preferable because the volume change due to water absorption is large. Also, as in this embodiment, when the incident light does not have to be polarized light, such as when it is arranged between the backlight 3 and the linearly polarizing plate 7 to improve the light utilization efficiency from the backlight 3 In addition, a film having optical anisotropy, such as PET (polyester terephthalate), can be applied on condition that the incident surface side is a base material. When transferring a transfer layer to another substrate, various substrates such as a PET film, a polyolefin film, a film with a release layer, and the like can be applied as long as unintentional peeling does not occur in the manufacturing process. Although various curable resins that can be subjected to a molding process can be applied to the molding resin layer 16, an ultraviolet curable resin is applied in this embodiment. In addition, in the state which heated the base material 15 and was softened, you may press to a shaping die and may perform a shaping process. In this case, the shaping resin layer 16 will be comprised with the base material 15. .

  Thus, the polarizer 4 is provided with a transparent layer that is transparent to electromagnetic waves in a wavelength band that restricts transmission on one surface of the polarizing layer 13 by laminating the base material 15 and the shaping resin layer 16. In the polarizer 4, a protective layer such as a hard coat layer is provided on the side surface opposite to the base material 15 side of the polarizing layer 13 with a transparent layer that is transparent to electromagnetic waves in a wavelength band that restricts transmission, if necessary. You may do it.

  The polarizer 4 can also be a transparent member such as quartz glass applied to the base material 15. In this case, a fine uneven shape related to the transparent solid dielectric portion 12 is produced by a molding process using a molding resin. However, the concave-convex shape of the fine structure according to the transparent solid dielectric portion 12 may be manufactured by, for example, forming a concave groove by an etching process. In this case, in the polarizer 4, a transparent layer made of a base material such as quartz glass is provided on the polarizing layer 13 instead of the transparent layer formed by stacking the base material 15 and the shaping resin layer 16.

〔Manufacturing process〕
FIG. 4 is a flowchart showing manufacturing steps of the polarizer 4. In this manufacturing process, the base material 15 made of a long transparent film material is provided in a form wound on a roll. In this manufacturing process, a concavo-convex shape is formed on the surface of the base material 15 by the concavo-convex shape manufacturing step SP2 while the base material 15 is pulled out and conveyed from the roll.

  More specifically, in this uneven shape manufacturing step, as shown in FIG. 5A, first, after applying an ultraviolet curable resin coating liquid to the base material 15, fine uneven shapes are formed on the peripheral side surface. While pressing and transporting the base material 15 to the peripheral side surface of the roll plate, which is a mold for molding, the ultraviolet curable resin is cured by irradiating ultraviolet rays, and then the cured ultraviolet curable resin is used. It peels from the roll plate integrally with the base material 15. As a result, as shown in FIG. 5B, in this step, the concave and convex grooves corresponding to the metal linear portions 11 are transferred to the surface of the base material 15 by transferring the fine irregularities formed on the peripheral side surface of the roll plate. The shaping resin layer 16 formed by producing No. 21 is produced. Accordingly, the concave groove 21 corresponds to the groove width corresponding to the line width Wm of the metal linear portion 11 that is equal to or shorter than the shortest wavelength of the wavelength band that restricts transmission, and also corresponds to the repetition pitch P of the metal linear portion 11. It is produced by the pitch.

  Then, the manufacturing process of the polarizer 4 arrange | positions a metal material in the concave groove | channel 21, and forms the metal linear part 11 in metal linear part preparation process SP3. More specifically, in this embodiment, as shown in FIG. 5C, a metal layer is formed on the entire surface of the concavo-convex shape formed by forming the concave groove 21 by vapor deposition, sputtering, electroplating, electroless plating, or the like. 22 is produced, and the metal linear part 11 is produced.

  Subsequently, in this manufacturing process, an extra metal layer is deleted by etching, polishing, cutting, or the like in the metal removing process SP4 as shown in FIG. In removing the metal layer, processing conditions are set according to the shapes described above with reference to FIG. More specifically, for example, when the metal layer is removed by etching, the end face of the metal linear portion 11 may be set to protrude by managing the type, concentration, temperature, and etching time of the chemical solution used for etching. it can. For example, when the metal layer is removed by polishing, the end face of the metal linear portion 11 is controlled by controlling the polishing agent used for polishing, the temperature of the polishing solution by the polishing agent, the concentration of the chemical added to the polishing solution, the pressing force, and the like. It can be set to project. Further, the metal removal step SP4 is performed by combining etching, polishing, cutting, and the like as necessary, as in the case of processing the end face by etching after cutting, for example.

  In this embodiment, these processes SP2 to SP4 are sequentially executed while transporting the base material 15 and then transported to a subsequent process process after being wound on a roll.

  In this way, after forming a concavo-convex shape formed by arranging a plurality of concave grooves with a groove width equal to or shorter than the shortest wavelength, the polarizer is formed between the adjacent metal linear portions by forming a metal linear portion. It can be set as the structure provided with the dielectric material part, and, thereby, abrasion resistance can be improved compared with the past. Further, mass productivity and production accuracy can be improved.

  Moreover, after producing a metal layer on the whole and removing the metal layer which concerns on a transparent solid dielectric part, a large area polarizer can be mass-produced efficiently and mass-productivity can be improved further. In addition, by producing a concavo-convex shape formed by arranging a plurality of concave grooves by a shaping process, a large-area polarizer can be efficiently mass-produced, and mass productivity can be further improved.

  In addition, by improving the mass productivity, wear resistance, and manufacturing accuracy in this way, by setting the end face of the transparent solid dielectric portion to protrude, the metal linear portion 11 is not damaged by the protruding portion. Thus, the scratch resistance can be further improved, and the reliability can be improved by effectively avoiding the deterioration of the optical characteristics associated with long-term use.

  Note that a step of making the surface of the metal layer transparent may be provided instead of or in addition to the metal removal step SP3. The transparency here is a treatment for making the surface of the metal layer transparent with respect to electromagnetic waves in the corresponding wavelength band. For example, by oxidizing the surface of the metal layer with aluminum, the aluminum on the surface of the metal layer is converted into aluminum oxide. It is executed by changing the quality. In addition, you may make it function the transparent layer produced in this way as a protective layer of a polarizer layer.

[Roll version]
FIG. 6 is a diagram for explaining the roll plate. The roll plate 30 is a mold for molding having a fine uneven shape on the peripheral side surface, and a fine uneven shape by a ridge corresponding to the concave groove 21 is formed on the peripheral side surface. In this embodiment, this ridge is formed so as to extend in the circumferential direction, whereby the concave groove 21 is formed so as to extend in the longitudinal direction of the base material 15 by shaping.

  In the roll plate 30, a base material 31 is formed in a cylindrical shape or a columnar shape made of a metal material that is easy to cut. In this embodiment, a copper pipe material is applied to the base material 31. In this smoothing process, after the peripheral side surface of the base material 31 is smoothed by cutting processing of the peripheral surface of the base material 31 using a cutting tool in the smoothing step, electrolysis is performed by a combination of an electrolytic elution action and a rubbing action by abrasive grains. The peripheral side surface of the base material 31 is made into a super mirror surface by a composite polishing method.

  Subsequently, in this cutting process, after the base material 31 is mounted on the cutting device in the cutting process, the tip of the cutting tool 32 is pressed against the peripheral side surface of the base material 31, and in this state, the base material 31 is moved as shown by an arrow B. While rotating, the cutting tool 32 is moved in the direction along the tube axis of the base material 31 as indicated by the arrow C, and the peripheral side surface of the base material 31 is cut into a spiral shape. Thereby, this manufacturing process produces the protruding item | line corresponding to the concave groove | channel 21 by the cross-sectional rectangular shape extended in the circumferential direction on the surrounding side surface of the base material 31. FIG. Note that the tip of the cutting tool 32 is formed in a comb-like shape so that a plurality of protrusions can be manufactured simultaneously and in parallel, thereby reducing the time required for manufacturing the roll plate in this step.

  In the extension direction of the ridges, the extension direction of the rotation shaft may be used as necessary, or may be inclined obliquely with respect to the rotation axis direction.

[Second Embodiment]
FIG. 7 is a diagram for explaining a roll plate manufacturing method according to the third embodiment. This embodiment is configured in the same manner as the above-described embodiment except that the roll plate manufacturing method is different.

  In the manufacturing process of this embodiment, a replica plate 41 using a lithographic plate formed by forming a concavo-convex shape by the concave groove 21 is manufactured by a forming process using a flat plate forming plate. In this manufacturing process, a plurality of the duplicate plates 41 are arranged in close contact with the surface plate 42 or separated by a predetermined interval (FIG. 7A). Thereafter, a metal layer 43 having a desired thickness is produced on the surface by electroforming with nickel or the like (FIG. 7B), and then the metal layer 43 is peeled off (FIG. 7C).

  Thus, in this step, a sheet-shaped plate (43) having a large area in which a plurality of duplicate plates are produced using one original plate, and fine unevenness is produced on the surface by tiling of the plurality of duplicate plates. Is made.

  In this manufacturing process, both end portions of the sheet-like plate (43) are connected so that the whole becomes a cylindrical shape, thereby forming a sleeve plate. This embodiment is a roll formed by inserting a core material in a cylindrical shape or a columnar shape into this sleeve plate and arranging the sleeve plate on the peripheral side surface of this core material, thereby producing a fine uneven shape related to the shaping process on the peripheral side surface. Make a plate.

  Even if a sleeve plate is produced by tiling a duplicate plate produced using one original plate as in this embodiment to produce a roll plate, the same effect as in the first embodiment can be obtained. . In this case, the inclination of the ridge formed on the peripheral side surface of the roll plate can be variously set by inclining and arranging the shaping plate used for tiling, and the roll plate with a desired inclination can be easily set. Can be produced.

  Instead of this, a resin sheet re-molded with a resin from the sheet plate (43) may be simply wound around the core material and fixed to form a roll plate, or the metal layer 43 may be electroformed. (FIGS. 15B and 15C), a sheet re-molded directly with resin may be wound around the core material as it is as a sheet-like plate (43) and fixed to form a roll plate.

[Third Embodiment]
In this embodiment, an image display device is configured by arranging an antireflection film made of a circularly polarizing plate produced by laminating a quarter-wave plate and a linearly polarizing plate on the panel surface of the image display panel. In the image display device of this embodiment, the polarizer according to the above-described embodiment is applied to the linearly polarizing plate constituting the antireflection film.

  As in this embodiment, a circularly polarizing plate formed by laminating a quarter wavelength plate and a linearly polarizing plate is arranged on the panel surface of the image display panel to prevent reflection, and a polarizer is attached to the linearly polarizing plate. Even if it applies, the same effect as the above-mentioned embodiment can be acquired. However, in this case, since it is necessary to suppress the reflectance of the light exit surface (observer side) of the polarizer, a light-absorbing metal material is preferably used. Alternatively, a metal blackening process or a multilayer structure of metal layers (using a light-absorbing material on the observer side) can be applied as necessary.

[Fourth Embodiment]
FIG. 8 is a diagram showing a polarizer applied to the liquid crystal display device according to the fourth embodiment of the present invention. The polarizer 34 is arranged on the backlight 3 side of the liquid crystal cell 5 in the direction in which the metal linear portion 11 is on the liquid crystal cell 5 side, instead of the linearly polarizing plate 7 and the polarizer 4. Here, the metal linear portion 11 is provided with a reflection suppressing layer 11B that suppresses reflection by the metal linear portion on the end surface on the liquid crystal cell 5 side which is the end surface on one side. Accordingly, in this liquid crystal display device, the light emitted from the backlight 3 is effectively used, and reflection by extraneous light incident from the liquid crystal cell 5 side is sufficiently suppressed to sufficiently prevent reflection.

Thus, in this embodiment, after the metal material made of aluminum or the like is disposed in the concave groove in the same manner as in the above-described embodiment to produce the main body portion 11A of the metal linear portion 11, the reflection suppressing layer is formed in the reflective layer producing step. 11B is provided. Here, although the reflection suppressing layer 11B can be applied with a material having a lower reflectance than the main body layer 11A, the metal material disposed in the concave groove is changed to black (this is a so-called blackening treatment). It may be formed, and a general blackening treatment material may be applied. For example, carbon, blackened Ni, blackened Cu, blackened Al, blackened Zn, or blackened Cr material using nano-particles Alternatively, a material containing any of these as a main component can be applied. Various low-reflectivity materials such as cupric oxide (CuO), aluminum oxide (Al ₂ O ₃ ), and triiron tetroxide (Fe ₃ O ₄ ) may also be applied. For the blackening process, for example, a method disclosed in JP 2012-208145 A can be applied. The blackened layer 11A can be applied with electroless plating, electrolytic plating, dry film formation, ink coating with nanoparticles, transfer of a stripe pattern produced by the shape of the blackened layer, etc. It is also possible to apply a treatment for blackening by treating with a chemical reaction.

  As described above, when the reflection suppression layer 11B is provided at the end of the metal linear portion, if the reflection suppression layer 11B is thin, sufficient antireflection cannot be achieved. It becomes difficult. Thereby, the reflection suppression layer 11B is produced with a thickness of 1 nm or more and 20 nm or less.

  In this embodiment, by arranging a polarizer having a low reflection layer on the liquid crystal cell side on the backlight 3 side of the liquid crystal cell 5, the light emitted from the backlight 3 can be used effectively, and the liquid crystal cell 5 Reflection by extraneous light entering from the cell 5 side can be sufficiently suppressed. Moreover, the field of application of this type of wire grid polarizer can be expanded by providing a polarizer by providing a reflection suppressing layer at one end of the metal linear portion.

[Fifth Embodiment]
FIG. 9 is a cross-sectional view showing a polarizer according to a fifth embodiment of the present invention in comparison with FIGS. 2 and 8, and more specifically, FIGS. 9A and 9B are first views. It is a figure which shows the polarizer of this embodiment by contrast with 4th Embodiment. In this embodiment, when forming the metal linear part 11 in a concave groove, the intermediate | middle layer 35 which reinforces adhesiveness is provided on a concave groove. Here, the intermediate layer 35 is not particularly limited, but SiO ₂ , SiC, or the like, which is mainly Si or a compound thereof, is preferable. Further, the thickness is 5 nm or more and 10 nm or less.

  For this reason, in this embodiment, after producing the concave groove by the shaping process, the intermediate layer 35 is produced by vapor deposition, sputtering or the like, and then the metal material related to the metal linear portion is arranged.

  In this embodiment, by providing the intermediate layer 35, the metal linear portion can be provided with high reliability, and as a result, the reliability of the polarizer and the liquid crystal display device can be improved.

[Other Embodiments]
The specific configuration suitable for the implementation of the present invention has been described in detail above. However, the present invention is not limited to the scope of the present invention, and various combinations of the above-described embodiments, and further the configuration of the above-described embodiments. Can be variously changed.

  That is, in the above-described embodiment, the case where the wavelength band that is applied to the image display device and restricts transmission is in the visible light range (wavelength of 380 nm to 800 nm) has been described. The present invention can be widely applied to the case where the transmission of light is limited. When the transmission of electromagnetic waves outside the visible light region is limited in this way, the transparent solid dielectric portion does not necessarily need to be transparent in visible light, and may be opaque in visible light.

  In the above-described embodiment, the case where the present invention is applied to an image display device has been described. However, the present invention is not limited thereto, and various optical devices such as an exposure device, a projector, illumination, sunglasses, a light control sheet, and the like can be used. It can be widely applied to a dimmer.

  Moreover, although the above-mentioned embodiment described the case where a polarizer was produced by the shaping process of the long film material using the shaping mold by the roll plate, the present invention is not limited to this, and a mold by a flat plate is used. The present invention can be widely applied to the case of manufacturing by processing the used single wafer.

DESCRIPTION OF SYMBOLS 1 Image display apparatus 2 Liquid crystal display panel 3 Backlight 4, 34 Polarizer 5 Liquid crystal cell 6, 7 Linearly polarizing plate 11 Metal linear part 11A Main part 11B Antireflection layer 12 Transparent solid dielectric part 13 Polarizing layer 15 Base material 16 Molding resin layer 21 Concave groove 22, 43 Metal layer 30 Roll plate 31 Base material 32 Byte 35 Intermediate layer 41 Replica plate 42 Surface plate

Claims (18)

In a polarizer that limits the transmission of incident electromagnetic waves according to the plane of polarization,
Provided with a polarizing layer responsible for the optical function as a polarizer,
The polarizing layer is
A plurality of metal linear portions made of a metal material with a line width equal to or less than the shortest wavelength of a wavelength band that restricts transmission are arranged apart in the direction of the line width,
A transparent solid dielectric portion made of a solid dielectric transparent to the electromagnetic wave in the wavelength band is provided between the adjacent metal linear portions,
The end surface of the said metal linear part which concerns on the thickness direction protrudes 20 nm or more from the end surface of the said transparent solid dielectric material part which adjoins. Polarizer. The polarizer of Claim 1. The cross-sectional shape of the said end surface which concerns on the width direction of the said metal linear part is a curved surface shape from which the center protrudes. The polarizer according to claim 1, wherein a metal film made of a material of the metal linear portion is provided on an end surface of the transparent solid dielectric portion. The polarizer according to claim 1, wherein a transparent layer that is transparent to electromagnetic waves in the wavelength band is provided on at least one surface of the polarizing layer. The polarizer according to claim 4, wherein the transparent layer is a protective layer for the polarizing layer. The polarizer according to claim 4, wherein the transparent layer is a transparent resin layer integral with the transparent solid dielectric part. The polarizer according to claim 4, wherein the transparent layer is a transparent resin layer integral with the transparent solid dielectric portion and a base material of the transparent resin layer. The metal material of the said metal linear part contains either aluminum, nickel, chromium, or silver. Claim 1, Claim 2, Claim 3, Claim 4, Claim 5, Claim 6, Claim 7 The polarizer in any one. In the method of manufacturing a polarizer that limits the transmission of incident electromagnetic waves according to the polarization plane,
Concavities and convexities that produce a concave-convex shape formed by arranging a plurality of concave grooves with a groove width equal to or shorter than the shortest wavelength of the wavelength band on a base material transparent to electromagnetic waves in a wavelength band that restricts transmission. Shape production process;
Metal forming a metal layer on the surface on which the concave groove is formed, thereby disposing a metal material in the concave groove to form a linear metal linear portion with a line width equal to or shorter than the shortest wavelength A linear part manufacturing process,
At least the metal layer between the adjacent concave grooves is removed, and the end surface of the metal linear portion in the thickness direction is projected by 20 nm or more from the end surface of the member related to the adjacent concave groove. Production method. The uneven shape manufacturing step includes
The method for manufacturing a polarizer according to claim 9, wherein the uneven shape is formed on the base material by a forming process using a forming mold. The metal linear part production process includes:
The metal layer is produced by any one of vapor deposition, sputtering, electroplating, electroless plating, chemical vapor deposition, atomic layer deposition, oxidation-reduction reaction, and nanoparticle deposition. A method for producing a polarizer according to claim 1. The polarizer according to claim 1, claim 2, claim 3, claim 4, claim 5, claim 6, claim 7, or claim 8 is provided on the exit surface side and / or entrance of the liquid crystal cell. Liquid crystal display device arranged on the surface side. The polarizer according to any one of claims 1, 2, 3, 4, 5, 6, 7, and 8 is a linearly polarized light on an incident surface side of a liquid crystal display panel. A liquid crystal display device integrated with a plate. The polarizer according to any one of claims 1, 2, 3, 4, 5, 6, 7, and 8 is disposed on a panel surface of an image display panel. Image display device. The metal linear part is:
A reflection suppressing layer that suppresses reflection of incident light is provided on an end surface of the transparent solid dielectric portion that protrudes from the end surface. Claims 1, 2, 3, 3, 4, and 5 The polarizer according to claim 6, claim 7, or claim 8. An intermediate layer that reinforces adhesion is provided between the transparent solid dielectric portion and the metal linear portion. Claims 1, 2, 3, 3, 4, and 5 The polarizer according to claim 6, claim 7, claim 8, or claim 15. The metal linear part production process includes:
The polarization according to any one of claims 9, 10, and 11, further comprising a step of forming a reflection suppressing layer that suppresses reflection of incident light at an end of the metal linear portion formed in the concave groove. Child manufacturing method. 17. The liquid crystal display device according to claim 15, wherein the polarizer according to claim 15 is disposed on the side surface of the backlight of the liquid crystal cell while the surface on which the antireflection layer is formed is held on the side surface of the liquid crystal cell. .

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