JP2016224284A - Polarizer, polarizer transfer body, image display device, manufacturing method for polarizer, and manufacturing method for polarizer transfer body - Google Patents

Abstract

A wire grid polarizer that enables mass production of a large-area product efficiently. In a polarizer that restricts transmission of incident electromagnetic waves according to a polarization plane, a metal linear portion is repeatedly formed with a pitch and a line width less than the shortest wavelength in a wavelength band that restricts transmission, The holding part 16 of the metal linear part 11 provided with the concavo-convex surface by the concave groove 12 is formed, and the metal linear part 11 is provided with a teardrop-shaped part formed by a cross-sectional teardrop shape on the bottom surface of the concave groove 12. . [Selection] Figure 2

Description

  The present invention relates to a wire grid polarizer.

  Conventionally, in a liquid crystal display device, a liquid crystal cell is formed by sandwiching a liquid crystal material by 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.

  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 recent years, liquid crystal display devices have been made thinner. In particular, portable liquid crystal display devices are required to be made thinner. As a result, the components of the liquid crystal display device are also required to be thinned.

  However, a polarizer using a sheet polarizer applied to such a liquid crystal display device has disadvantages that heat resistance is poor and 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 conventional wire grid polarizer has a problem that it is difficult to efficiently mass-produce a large-area product.

JP 2006-330521 A JP 2012-27221 A

  This invention is made | formed in view of such a condition, and it aims at enabling it to mass-produce a large area product efficiently regarding a wire grid type polarizer.

  The present inventor has conducted extensive research to solve the above problems, and after depositing a metal material on an uneven surface formed by repeatedly producing ridges, the metal material remains on the top of the ridges after etching. As a result, the present inventors completed the present invention with the idea that a metal linear part is prepared by holding the metal linear part with a transparent resin material and peeling it from the substrate to produce a polarizer. It was.

(1) In a polarizer that limits the transmission of incident electromagnetic waves according to the plane of polarization,
A metal linear part is repeatedly produced with a pitch and a line width less than the shortest wavelength of a wavelength band that restricts transmission,
A holding part of the metal linear part provided with an uneven surface by a plurality of concave grooves is formed,
The metal linear portion is
A polarizer comprising a teardrop-shaped portion made in a teardrop-shaped cross section on the bottom surface of the concave groove.

  According to (1), after depositing the metal material which concerns on a metal linear part on the uneven surface provided with the protruding item | line corresponding to a concave groove, a metal linear part can be produced by etching. In addition, after that, it can be produced by forming a holding part with a transparent resin material so as to hold the metal linear part produced in this way. Can be mass-produced well.

(2) In (1),
The holding part is
A polarizer which is a transparent resin layer and is held on the surface of a base material by a transparent film material.

  According to (2), a polarizer can be produced with a more specific configuration.

(3) In (1) or (2),
A polarizer in which the metal linear portion is formed by a portion having a rectangular cross-section related to the concave groove and a portion having the teardrop shape.

  According to (3), the metal linear part with a large aspect ratio can be formed by providing the part by the cross-sectional rectangular shape which concerns on the concave groove of a holding | maintenance part.

  (4) An image display device comprising the polarizer according to any one of (1), (2), and (3).

  According to (4), it is possible to provide an image display device using a wire grid type polarizer capable of efficiently mass-producing a large-area product.

(5) In the polarizer transfer body according to the wire grid polarizer,
An uneven surface with a plurality of ridges is formed on the surface of the substrate,
At the top of the ridges of the concavo-convex surface, a metal linear part is produced by a teardrop shape in cross section
A polarizer transfer body having a holding portion for holding the metal linear portion.

  According to (5), after depositing the metal material which concerns on a metal linear part on the uneven surface provided with the protruding item | line, a metal linear part can be produced by etching. Thereafter, the holding portion can be formed of a transparent resin material. Thereby, regarding the wire grid type polarizer, a transfer body of the polarizer can be mass-produced efficiently with a large area.

(6) In (5),
A shaping resin layer is provided on the surface of the substrate,
A polarizer transfer body in which the uneven surface is produced by a molding treatment of the molding resin layer.

  According to (6), it is possible to provide a transfer body of a polarizer with a more specific configuration by producing an uneven surface by a shaping process.

(7) In (5) or (6),
The uneven surface is provided with an adhesion enhancing layer,
The metal linear portion is a transfer body of a polarizer disposed on the top of the ridge through the adhesion reinforcing layer.

  According to (7), damage to the metal linear portion can be reduced. Further, in the case of producing an uneven surface with a shaping resin, this adhesion strengthening layer can function as a barrier layer so as not to impair the deposition of the metal material.

  (8) An image display device in which the metal linear portion and the holding portion are transferred and held by the polarizer transfer body according to any one of (5), (6), and (7).

  According to (8), with respect to the wire grid type polarizer, it is possible to efficiently mass-produce a large-area product and to provide an image display device including the polarizer.

(9) In the transfer body of the polarizer according to the wire grid polarizer,
A metal linear part is repeatedly produced with a pitch and a line width less than the shortest wavelength of a wavelength band that restricts transmission,
A holding part of the metal linear part provided with an uneven surface by a plurality of concave grooves is formed,
The metal linear portion is
A polarizer transfer body comprising a teardrop-shaped portion prepared in a cross-sectional teardrop shape on the bottom surface of the concave groove.

  According to (9), the metal linear part can be produced by depositing the metal material related to the metal linear part on the uneven surface provided with the ridge corresponding to the concave groove and then etching. Moreover, it can produce after that by forming the holding | maintenance part of the metal linear part produced in this way, Thereby, a large area product can be efficiently mass-produced regarding a wire grid type polarizer.

(10) In (9),
The holding part is
A transfer body of a polarizer which is a transparent resin layer and is held on the surface of a support substrate made of a transparent film material.

  According to (10), a polarizer can be produced with a more specific configuration.

(11) In (9) or (10),
A transfer body of a polarizer in which the metal linear portion is formed by a portion having a rectangular cross section related to the concave groove and a portion having a teardrop shape.

  (11) According to (1), a metal linear portion having a large aspect ratio can be formed by providing a portion having a rectangular cross-sectional shape related to the concave groove.

  (12) An image display device in which the metal linear portion and the holding portion are transferred and held from the polarizer transfer body according to any one of (9), (10), and (11).

  (12) According to (12), it is possible to provide an image display device using a wire grid type polarizer capable of efficiently mass-producing a large-area product.

(13) In the method for manufacturing a polarizer according to the wire grid polarizer,
A process of producing a transfer body for producing a transfer body;
A polarizer production step of producing a polarizer from the transfer body by a transfer method,
The production process of the transfer body includes:
An uneven surface preparation step for preparing an uneven surface with a plurality of protrusions on the surface of the support substrate,
A metal material deposition step of depositing a metal material on the uneven surface;
Etching the metal material deposited on the concavo-convex surface to produce a metal linear portion having a cross-sectional teardrop shape at the top of the ridge, and
A holding part preparation step of preparing the transfer body by applying a transparent resin material to the metal linear part to prepare a holding part for holding the metal linear part,
The polarizer production process includes:
The manufacturing method of a polarizer provided with the transfer process which transfers the said metal linear part and holding | maintenance part from the said transfer body, and peels a support base material integrally with the said uneven surface.

  According to (13), the metal linear part can be manufactured by depositing the metal material related to the metal linear part after the production of the concave / convex surface provided with the ridges, and then etching. Further, after forming the holding portion with a transparent resin material, it can be manufactured by peeling, and as a result, a large-area product can be mass-produced efficiently with respect to the wire grid polarizer.

(14) In (13),
The production process of the polarizer,
The manufacturing method of a polarizer provided with the arrangement | positioning process of the metallic material which peels the said support body base material and arrange | positions a metallic material to the concave groove corresponding to the said protruding item | line formed in the said holding | maintenance part by the said transfer process.

  According to (14), a metal linear part having a large aspect ratio can be formed by further disposing a metal material in a concave groove formed by peeling the holding part.

(15) In the method for producing a polarizer transfer body according to a wire grid polarizer,
An uneven surface preparation step of forming an uneven surface with a plurality of protrusions on the surface of the first support substrate;
A metal material deposition step of depositing a metal material on the uneven surface;
Etching the metal material deposited on the concavo-convex surface to produce a metal linear portion having a cross-sectional teardrop shape at the top of the ridge, and
The manufacturing method of the transfer body of a polarizer provided with the holding part production process which applies the transparent resin material to the metal linear part, and produces the holding part which holds the metal linear part.

  According to (15), the metal linear portion can be manufactured by depositing the metal material related to the metal linear portion after the concave-convex surface having the ridges is formed, and then etching. Further, it can be produced by subsequently forming a holding portion with a transparent resin material, whereby a large-area product can be efficiently mass-produced with respect to the transfer body of the wire grid polarizer.

(16) In (15),
A transfer step of laminating the holding portion on a second support substrate and peeling the first support substrate integrally with the uneven surface;
A polarizer comprising: a metal material disposing step of disposing the metal material in a concave groove corresponding to the convex strip formed on the holding portion by peeling the first support substrate by the transfer step; Production method of transcription.

  According to (16), by further disposing a metal material in the concave groove, it is possible to provide a polarizer transfer body in which a metal linear portion having a large aspect ratio is formed.

  ADVANTAGE OF THE INVENTION According to this invention, a large area product can be efficiently mass-produced regarding a wire grid type polarizer.

It is a figure which shows the image display apparatus which concerns on 1st Embodiment of this invention. It is a figure which shows the polarizer applied to the image display apparatus of FIG. It is a figure where it uses for description of the transfer film (transfer body) which concerns on the polarizer of FIG. It is a figure which shows the other example of the transfer film of FIG. It is a figure which shows the polarizer by the transfer film of FIG. It is a flowchart which shows the manufacturing process of the transfer film of FIG. It is a figure where it uses for description of the manufacturing process of FIG. It is a figure where it uses for description of a lamination process. It is a figure where it uses for description of a roll version. It is a figure which shows the polarizer which concerns on 1st Embodiment of this invention. It is a figure where it uses for description of the transfer film (transfer body) which concerns on the polarizer of FIG. It is a graph which shows the detail of an Example and a comparative example. It is a graph which shows the characteristic in the visible light region of an Example and a comparative example. It is a graph which shows the characteristic in the infrared region of an Example and a comparative example.

[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 linear polarizers 6 and 7 as polarizers, and the liquid crystal cell 5 is formed by sandwiching a liquid crystal material by a glass substrate on which a transparent electrode 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 linear polarizing plate 7 together with an adhesive such as an ultraviolet curable resin.

[Polarizer]
FIG. 2 is a cross-sectional view 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, in accordance with the polarization plane, and is provided with a polarizer layer 13 that has an optical function as a polarizer. In the polarizer 4, a plurality of metal linear portions 11 are arranged on the polarizer layer 13 so as to be separated in the line width direction. Here, the metal linear portion 11 is formed of a metal material having a line width Wm less than the shortest wavelength λmin in the wavelength band of the electromagnetic wave that restricts transmission. Further, the metal linear portions 11 are repeatedly arranged regularly or irregularly by the pitch P less than the shortest wavelength λmin. As a result, the interval Wt between the adjacent metal linear portions 11 has a duty ratio D (= Wm / P = Wm / (Wm + Wt)) of 0.2 to 0.8, preferably 0.3 to 0.7. It is produced as follows. The line width Wm is defined by a width viewed from a direction orthogonal to the extending direction of the metal linear portion 11 and the repeating direction of the metal linear portion 11. Note that the shortest wavelength λmin may be set to the shortest wavelength 380 nm or less in the visible light region when the transmission is limited to the entire wavelength band in the visible light region as applied to the image display device as in this embodiment. 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.

  Further, the metal linear portion 11 is formed such that the thickness H is equal to or shorter than the shortest wavelength λmin with respect to the shortest wavelength λmin. 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 the pitch P, the line width Wm, and the thickness H by simulation based on the refractive index n and the 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. Thereby, for example, when a sufficient extinction ratio is secured at a wavelength of 550 nm, a general ultraviolet curable resin (n = n) is used between the metal linear portions 11 and the metal linear portions 11 (which will be described later). 1.5, k = 0 at 550 nm), the pitch P is 75 nm to 175 nm, preferably 100 nm to 150 nm. The polarizer 4 can also be manufactured so as to correspond to the wavelength band in the infrared region (wavelength 780 nm to 2500 nm). For example, the center wavelength 940 nm can be set as the design reference wavelength to ensure desired optical characteristics. As described above, by introducing suitable values such as the pitch P and the line width Wm, it is possible to limit the transmission of the incident light in the visible light region and the infrared region according to the polarization plane.

  Thus, the polarizer 4 is more specifically visible light from the viewpoint of ensuring sufficient P-wave transmittance for incident light in the visible light region and infrared region, and further ensuring a sufficient extinction ratio. From the viewpoint of securing a P-wave transmittance and extinction ratio equal to or higher than those of conventional sheet polarizers for incident light in the infrared region and infrared region, the repetition pitch P of the metal linear portions 11 is 100 nm or more and 200 nm or less, Preferably, the thickness (height) H of the metal linear portion 11 is set to 100 nm to 200 nm, preferably 130 nm to 170 nm.

  The polarizer 4 has a holding part 16 formed of a transparent resin material, and the holding part 16 holds the metal linear part 11 so as to wrap all or part of the metal linear part 11. In the polarizer 4, a concave / convex surface is produced by repeatedly forming a concave groove 12 having a flat bottom on one surface of the holding portion 16. The metal linear portion 11 is formed on the bottom surface of the concave groove 12 in a teardrop shape in cross section. Here, this cross-sectional shape is a cross-sectional shape in the width direction of the metal linear portion 11. That is, the metal linear portion 11 is in contact with the bottom surface of the concave groove 12 at approximately the center of the bottom surface of the concave groove 12, and the line width gradually increases as the distance from the bottom surface to the other surface side of the holding portion 16 increases. It is produced with a rounded cross-sectional shape.

  In the polarizer 4, the aspect ratio h / w, which is the ratio of the width w of the ridge between adjacent concave grooves 12 and the depth h of the groove, is 1 to 4, more preferably 2 to 3. 5 or less, and thus can be manufactured efficiently and accurately by a manufacturing method described later.

  Although the metal linear part 11 can widely apply, for example, metals, alloys, metal compounds, and the like related to various conductors, a metal made of any of aluminum, nickel, chromium, silver, an alloy made of any of these metals, It is desirable to apply these metal compounds. From the viewpoint of efficiently reflecting electromagnetic waves that restrict transmission, it is desirable to use metals, alloys, and compounds having high reflectivity such as aluminum, nickel, and silver, and aluminum is particularly preferable for visible light. 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.

  Further, the metal linear portion 11 may be made of a single material or a laminated structure of a plurality of materials. In the case of manufacturing by laminating a plurality of materials in this way, the visibility and contrast of the display screen are improved by applying a black material having a low reflectance on the liquid crystal layer side compared to the backlight 3 side. In addition, the utilization efficiency of backlight light can be improved.

  The holding part 16 is prepared by disposing and curing a coating liquid made of a transparent resin so as to penetrate between the adjacent metal linear parts 11 and further to cover the metal linear parts 11 in the example of FIG. Is done. As a result, the polarizer 4 is configured to prevent mechanical damage of the metal linear portion 11 and to ensure sufficient mechanical strength. Here, various types of transparent resin materials applicable to this type of optical film can be widely applied to the holding portion 16, for example, an ultraviolet curable resin can be applied.

  In the polarizer 4, a base material 17 made of a transparent film material is disposed on the other surface side of the holding portion 16, and the holding portion 16 is held on the base material 17 by an adhesive such as an ultraviolet curable resin. The polarizer 4 is laminated and integrated with the linear polarizing plate 7 on the side surface opposite to the holding portion 16 of the base material 17 or the uneven surface of the holding portion 16. The uneven surface of the holding portion 16 may be a smooth surface by coating with a transparent resin material.

  Here, as the base material 17, various film materials applicable to this type of optical film can be widely applied. Specifically, PET (polyester terephthalate), COP (cycloolefin polymer), TAC (tri-olefin) Acetyl cellulose) film or the like can be applied.

  In the polarizer 4, the metal linear portion 11 and the holding portion 16 are produced by transferring to a substrate 17 by a transfer method from a transfer film that is a transfer body for a polarizer. Here, the transfer method means that, 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 the layers are laminated to produce a transfer body (transfer film), the layer formed on the support is finally laminated on the substrate (transferred layer) according to the process, demand, etc. In this method, a desired layer is formed on the base material by bonding and laminating on the base material and then peeling off and removing the support. Here, when the support is peeled and removed, the form can be selected as appropriate. For example, it is possible to provide a layer made of a support on the holding part 16 by separately providing a support separately from the support base material and transferring the separately provided support integrally with the holding part. it can. Since the outermost surface of this layer reflects the film surface, a smooth surface can be obtained. Moreover, if it does in this way, the effect of thinning which eliminated the thickness of the support base material can be acquired. In addition, by making the support used for transfer integrally with the holding portion in this way softer than the material of the holding portion 16 and having a good adhesiveness, the transfer is performed while leaving the support only in the concave groove 12 which is a gap portion. The outermost surface of the support 16 can be easily smoothed by further thinning and peeling process. In this case, low reflection performance can be imparted by appropriately adjusting the refractive index of the support so as to be equal to or lower than the refractive index of the holding portion. In addition, by setting the refractive index of the surface mainly facing the viewing side to be low, suitable low reflection performance can be obtained regardless of the orientation of the polarizer 4. In the following, a layer used for transfer is referred to as a transfer layer. Here, in the polarizer 4, the transfer layer is the metal linear portion 11 and the holding portion 16, and the substrate to be transferred is the base material 17. The linear polarizer 7 is used as a substrate to be transferred, and the metal linear portion 11 and the holding portion 16 are directly laminated on the linear polarizing plate by a transfer method, and the polarizer is formed only by the metal linear portion 11 and the holding portion 16. May be configured.

[Transcript]
FIG. 3 is a view showing a transfer film which is a film-shaped transfer body used for production of the polarizer 4. In the transfer film 14, a concavo-convex surface including a ridge 22 corresponding to the concave groove 12 of the holding portion 16 is formed on the support base material 25. Here, in this embodiment, the concavo-convex surface is produced by a forming process using a forming mold. Further, this shaping process is executed by a shaping process of the shaping resin layer 26 disposed on the support base material 25. Here, an ultraviolet curable resin or the like can be applied to the shaping resin. In addition, the support base material 25 may be heated and softened and pressed against the molding die to perform a molding process. In this case, the molding resin layer 26 is constituted by the support base material 25. Will be. Here, as the support base material 25, various film materials applicable to this type of transfer film can be widely applied. Specifically, PET (polyester terephthalate), COP (cycloolefin polymer), TAC ( A triacetyl cellulose) film or the like can be applied.

  In addition, a transfer material may be produced in a plate shape by applying a glass material or the like to the support substrate 25 and producing an uneven surface by photoetching. In this case, the unevenness remaining after transferring the transfer layer The surface can be used repeatedly to produce a transfer body.

The transfer film 14 functions as a barrier layer that enhances the adhesion between the metal linear portion 11 and the ridges 22 on the surface of the uneven surface, and further prevents volatilization of gas components from the shaping resin layer 26. Thus, the adhesion reinforcing layer 27 is formed. Here, the adhesion strengthening layer 27 is formed of a SiO ₂ layer in this embodiment, although various kinds of configurations that enhance the adhesion and can serve as a barrier layer can be applied.

  In the transfer film 14, a metal linear portion 11 is formed on the top of the ridge 22 formed in this manner, and the transparent resin is formed so as to cover the metal linear portion 11 and enter between the ridges 22. The holding part 16 is formed by coating, drying and curing the material.

  As shown in FIG. 4A, the holding portion 16 may be formed so that the thickness at the tip end portion of the ridge is equal to the thickness H of the metal linear portion 11, as shown in FIG. As shown, the thickness may be smaller than that of the metal linear portion 11. However, in this type of polarizer, by reducing the refractive index between the adjacent metal linear portions 11, characteristics (extinction ratio, transmittance, etc.) are improved, so that the metal linear shape from the end face of the holding portion 16. It is desirable to reduce the thickness of the holding portion 16 so that the portion 11 protrudes greatly. However, when the thickness of the holding part 16 is reduced, the function of holding the metal linear part 11 is impaired. Moreover, when the holding | maintenance part 16 jumps out from the front-end | tip of the metal linear part 11, the thickness of a polarizer will become thick by the part which protruded. Thereby, it is desirable that the thickness of the holding portion 16 (thickness at the convex top portion) is not more than the thickness H of the metal linear portion 11 and not less than 1/2 of the thickness H. FIG. 5 shows a polarizer using the transfer film shown in FIGS. 4A and 4B in comparison with FIGS. When the thickness of the holding portion 16 is set to be equal to or less than the thickness H of the metal linear portion 11 (FIG. 4B), the thickness of the holding portion 16 is smaller than that of the metal linear portion 11, as shown in FIG. A thick part is locally formed in the holding part 16, and the metal linear part 11 and the holding part 16 are held on the base material 17 by this part. Instead of this, the holding portion 16 may be held on the base material 17 via an intermediate support having a frame shape.

〔Manufacturing process〕
[Transfer manufacturing process]
FIG. 6 is a flowchart showing the manufacturing process of the transfer film 14. This manufacturing process provides a base material 25 made of a long transparent film material in a form wound on a roll. In this manufacturing process, an uneven surface is formed on the surface of the base material 25 by the uneven surface preparation step SP2 while the base material 25 is pulled out and conveyed from the roll.

  More specifically, in this uneven surface preparation step, as shown in FIG. 7 (A), first, an ultraviolet curable resin coating solution is applied to the substrate 25 and then shown in FIG. 7 (B). In this way, the ultraviolet curable resin is cured by irradiating ultraviolet rays while pressing and transporting the base material 25 to the peripheral side surface of the roll plate 30 which is a mold for molding having fine irregularities formed on the peripheral side surface. After that, the cured ultraviolet curable resin is peeled off from the roll plate 30 together with the substrate 25. As a result, the fine uneven shape formed on the peripheral side surface of the roll plate 30 is transferred, and the ridges 22 corresponding to the metal linear portions 11 are formed on the surface of the substrate 25 as shown in FIG. An uneven surface is produced.

  Subsequently, in this manufacturing process, after the adhesion strengthening layer 27 is formed on the uneven surface by sputtering or the like in the base layer preparation process SP3, as shown in FIG. 7D, vapor deposition and sputtering are performed in the metal material deposition process SP4. A metal material related to the metal linear portion 11 is deposited on the uneven surface formed by forming the adhesion strengthening layer 27 by, for example. Here, although this metal material is deposited on the entire surface of the concavo-convex surface, it is preferentially deposited on the top of the ridge 22 as compared to the groove between the adjacent ridges 22. As a result, the metal material 20A is deposited with a sufficient deposition amount (thickness) at the top of the ridge 22, whereas the groove between the ridges 22 is markedly larger than the top of the ridge 22. Therefore, the metal material 20B is deposited with an extremely small deposition amount (film thickness).

  Thereby, in this embodiment, in the subsequent etching step SP5, the metal material on the uneven surface can be etched, and the metal material can be left only on the top of the ridge 22 to form the metal linear portion 11. More specifically, for example, after aluminum is applied to the metal material and the metal material is deposited on the top of the ridge 22 with a thickness of 100 nm (the thickness at the top of the ridge 22), the concentration is 0.1 mol / L, the temperature The metal linear part 11 can be produced by immersing it in an aqueous sodium hydroxide solution at 25 ° C. for 50 seconds so that no metal material remains in the groove between the ridges 22 and with a teardrop-shaped cross-sectional shape. Note that when the depth h is increased with respect to the width w of the groove portion, the amount of the metal material deposited on the bottom surface of the groove portion is reduced accordingly, so that only the metal material deposited in the groove portion is selectively removed. It becomes easy to produce the metal linear part 11, and it becomes easy to manage an etching process. Thus, the aspect ratio h / w, which is the ratio of the groove width w between adjacent ridges 22 and the groove depth h, is 1 or more and 4 or less, more preferably 2 or more and 3.5 or less. The metal linear part 11 can be produced efficiently and accurately. Needless to say, dry etching by vapor phase may be applied instead of wet etching by such a solution. For the deposition of the metal material, electrolytic plating, electroless plating, CVD, or the like may be applied.

  Subsequently, in the holding part manufacturing step SP6, the manufacturing process is performed by applying the coating liquid for the holding part 16 to the surface of the concavo-convex surface formed by forming the metal linear part 11, drying it, and curing it. The holding part 16 is produced (FIG. 3). In this manufacturing process, the transfer film 14 is thus produced in the shape of a long film, wound around a roll, and conveyed to the manufacturing process of the polarizer in a roll shape.

[Polarizer manufacturing process]
In the manufacturing process of the polarizer, the transfer film having a long film shape is pulled out from the roll and conveyed, and in the transfer process, the substrate 17 is laminated and integrated with the base material 17 having the same long film shape. 25 is peeled off integrally with the shaping resin layer 26. Thereby, in the manufacturing process of a polarizer, a transfer layer (a metal linear part and a holding | maintenance part) is transcribe | transferred from the transfer film which is a transfer body with a transfer method, and a polarizer is produced by the shape of a long film. In this manufacturing process, the polarizer 4 having a long film shape is wound around a roll and conveyed to the next process by the roll shape.

[Lamination process]
Here, the linear polarizing plate 7 by the sheet polarizer is produced by stretching, and as a result, the winding body 36 of the linear polarizing plate 7 provided by the roll shows the transmission axis direction by an arrow in FIG. The width direction is the transmission axis direction. Accordingly, in this embodiment, in the manufacturing process of FIG. 6, by using the roll plate 30 in which the protrusions are produced in the direction extending in the circumferential direction, the support base material 25 is extended in the longitudinal direction. The transfer film 14 is manufactured in the shape of a long film so that the ridges 22 are prepared in this way, and the width direction of the support base material 25 thus becomes the transmission axis direction.

  Further, the transfer layer is transferred from the long film-shaped transfer body thus produced to the long film-shaped base material 17 so that the width direction of the base material 17 becomes the transmission axis direction. The polarizer 4 is produced according to the shape. In the laminating process, the polarizer 4 is pulled out from the winding body 35 of the polarizer 4 having the long film shape thus produced and conveyed, and the straight line having the same long film shape is transferred from the linear polarizing plate winding body 36. The polarizing plate 7 is drawn out and laminated and integrated, and then the sheet is cut into a rectangular shape suitable for arrangement in the liquid crystal cell 5.

  In this way, the transmission axis direction is set so as to correspond to the transmission axis direction of the linear polarizing plate to produce a transfer film and a polarizer, and the linear polarizing plate is laminated and integrated in the state of a long film shape. Thereafter, the sheet can be cut to achieve more efficient production.

[Roll version]
FIG. 9 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 concave groove corresponding to the ridge 22 is formed on the peripheral side surface. In this embodiment, the concave groove is formed with a groove width corresponding to the width of the ridge 22 so as to extend in the circumferential direction. The ridge 22 is produced.

  In the roll plate 30, a base material 41 is formed in a cylindrical shape or a columnar shape made of a metal material that can be easily cut. In this embodiment, a copper pipe material is applied to the base material 41. In this smoothing process, after the peripheral side surface of the base material 41 is smoothed by cutting processing of the peripheral surface of the base material 41 using a cutting tool in the smoothing step, the electrolysis is performed by a combination of the electrolytic elution action and the rubbing action by the abrasive grains. The peripheral side surface of the base material 41 is made into a super mirror surface by a composite polishing method.

  Subsequently, in this manufacturing process, after the base material 41 is mounted on the cutting device in the cutting process, the tip of the cutting tool 42 is pressed against the peripheral side surface of the base material 41, and in this state, the base material 41 is moved as shown by an arrow B. While rotating, the cutting tool 42 is moved in the direction along the tube axis of the base material 41 as indicated by the arrow C, and the peripheral side surface of the base material 41 is cut into a spiral shape. Thereby, this manufacturing process produces the concave groove | channel corresponding to the protruding item | line 22 in the surrounding side surface of the base material 41 by the cross-sectional rectangular shape extended in the circumferential direction. Note that the cutting edge 42 is formed in a comb-like shape so that a plurality of concave grooves can be formed simultaneously and in parallel, thereby reducing the time required for producing the roll plate in this step. The manufacturing method of the cutting tool 42 having such a fine comb-tooth shape is not particularly limited, but high energy beam processing, lithography processing, chemical Et or precision cutting methods generally known as a fine precision processing method for achieving these are used. They can be selected as appropriate and can be produced by freely combining them.

[Second Embodiment]
FIG. 10 is a diagram for explaining a polarizer according to the second embodiment of the present invention. The image display device of this embodiment is configured in the same manner as in the first embodiment except that this polarizer 54 is applied instead of the polarizer 4. The polarizer 54 is filled with a metal material in the concave groove 12 of the holding portion 16, thereby connecting the portion having the cross-sectional teardrop shape and the portion having the rectangular cross-section, thereby having a vertical arrow 13 dimension. A metal linear part 51 having an aspect ratio is formed. In this polarizer 54, the holding portion 16 and the metal linear portion 51 are laminated on the base material 17 by a transfer method so that the concave groove 12 side becomes the linearly polarizing plate 7 side. With this process, not only a high aspect ratio but also a display or a window that emits light and enters from the lower side of FIG. 10, for example, can widen the opening on the light incident side and improve performance. . In addition, it may replace with the lamination | stacking to the base material 17, and you may make it laminate | stack directly on the linear polarizing plate 7. FIG.

  FIG. 11 is a view showing a transfer film according to the polarizer 54. In the transfer film 55, the holding part 16 and the metal linear part 51 are arranged on a support base material 56. The transfer film 55 transfers the holding portion 16 and the metal linear portion 11 from the transfer film (transfer body) 14 described above with reference to FIG. 3 to the support substrate 56 by the transfer method, and then uses the metal linear portion 11 as an electrode. By the set electroforming process, the metal material 58 is selectively disposed in the concave groove 57, and thereby the metal having the same effect as FIG. 10 by the shape in which the portion having the cross-sectional teardrop shape and the portion having the rectangular cross-section shape are connected. A linear portion 51 is formed. Instead of electroforming, a metal material may be deposited on the entire surface, and then the metal material at the convex portions may be removed by etching to produce the metal linear portion 51. Alternatively, the metal linear portion 51 may be produced by depositing a metal material on the entire surface and then making the surface transparent.

  Thereby, in this embodiment, the metal linear part 51 is produced with a high aspect ratio that is thicker than the line width, and a polarizer can be produced with higher performance. In this case, the thickness of the metal linear portion can be increased later, so that the metal linear portion can be manufactured with various thicknesses.

  In addition, the portion having a rectangular cross section related to the concave groove can be applied with a material different from the teardrop-shaped portion, or can be a laminated structure made of a plurality of materials different from the teardrop-shaped portion. The material on the front side (the part opposite to the teardrop-shaped part) has a lower reflectance than the material on the teardrop-shaped part, and a black material is selected. Contrast can be improved.

  In addition, in the transfer film 55, the metal linear part 51 and the holding part 16 are directly laminated on the linearly polarizing plate 7 by the transfer method using the linearly polarizing plate 7 as a substrate to be transferred. A polarizer may be configured only by the holding unit 16.

〔Example〕
FIG. 12 is a chart showing detailed configurations of the examples and comparative examples, and FIGS. 13 and 14 are charts showing measurement results of the examples and comparative examples according to the detailed configurations of FIG. FIG. 12 shows the dimensions of the respective parts of the example and the comparative example in the transfer film stage (configuration shown in FIG. 3). The measurement results in FIGS. 13 and 14 are the measurement results in the transfer film stage shown in FIG. It is. Here, in the examples and comparative examples, the width of the ridges 22 (pitch P−width w) is 53.6 nm. Example 1 is a sample that was actually used for measurement of characteristics, and was used for measurement of characteristics without the holding unit 16 being provided. In Example 1, the pitch P of the metal linear portions 11 is set to 100 nm, the metal linear portions 11 are made of aluminum, and the width (aluminum width) Wm of the metal linear portions 11 is set to 25 nm. (Aluminum height) H was set to 90 nm. Further, an SiO ₂ layer was applied to the adhesion strengthening layer (oxide film) 27, and the layer was produced with a thickness of 10 nm. The aluminum oxide film was measured at about 2.5 nm.

  The second embodiment is an embodiment based on a simulation based on the configuration of each part of the first embodiment. Examples 3 to 7 and Comparative Example 1 are examples based on the same simulation, and the holding unit 16 sets the refractive index n to a value of 1. In Example 3, the width Wm of the metal linear portion 11 was 40 nm, the height H was 145 nm, and the aluminum oxide film was 5 nm. In addition, Example 4, Example 5, and Comparative Example 1 were configured the same as Example 3 except that the pitch P was 150 nm, 200 nm, and 300 nm, respectively. In addition, Examples 6 and 7 were configured in the same manner as Example 3 except that the height H of the metal linear portion 11 was set to 100 nm and 200 nm, respectively.

  FIG. 13 is a diagram showing measurement results at a wavelength of 550 nm, which is the center wavelength in the visible light region of these examples and comparative examples. In FIG. 13, Tp and Ts are P wave and S wave transmittances, and Rp and Rs are P wave and S wave reflectances. The extinction ratio is Tp / Ts, and the polarization degree is (Tp−Ts) / (Tp + Ts). According to FIG. 13, except for the comparative example, a polarization degree of 90 or more can be secured, the P wave transmittance Tp can be secured 80% or more, and the P wave reflectance Rp can be kept 10% or less. Thus, it can be seen that the optical characteristics as a polarizer can be sufficiently secured with respect to the transmitted light by sufficiently securing the extinction ratio. On the other hand, in the comparative example, the degree of polarization, the P wave transmittance, the P wave reflectance, and the extinction ratio cannot be ensured sufficiently, so that the characteristics as a polarizer with respect to the transmitted light are still insufficient in practice. I understand that. Although the measurement result of FIG. 13 is a measurement result at a wavelength of 550 nm, similar characteristics were confirmed in the visible light range of a wavelength of 380 nm to 780 nm. In addition, it is judged that the characteristic deterioration in the comparative example is caused by the fact that the groove width between the ridges is wider than the width of the ridges (width of the metal linear portion). The interval Wt between the portions 11 is such that the duty ratio D (= Wm / P = Wm / (Wm + Wt)) is 0.2 to 0.8, preferably 0.3 to 0.7.

  FIG. 14 is a chart showing measurement results in the infrared region. Examples 6 and 7 are omitted from FIG. 14 because they are not simulated. FIG. 14 shows the measurement results at a representative wavelength of 940 nm that represents the infrared region (wavelength of 780 nm to 2500 nm). According to FIG. 14, it can be seen that the characteristics are improved as compared with the visible light region. Although FIG. 14 shows the measurement result at a wavelength of 940 nm, the same characteristics as the representative wavelength of 940 nm were confirmed in the wavelength range of 780 nm to 2500 nm. Thus, according to these Examples 1 to 5, the pitch P is set to 100 nm or more and 200 nm or less, and the thickness (height) H is set to 100 nm or more and 200 nm or less, and polarized light with sufficient characteristics in a wide wavelength band of visible light region and infrared region. It turns out that the function as a child can be secured.

[Other Embodiments]
The specific configuration suitable for the implementation of the present invention has been described in detail above. However, the present invention can be combined with the configuration of the above-described embodiment or the configuration of the above-described embodiment without departing from the spirit of the present invention. Various changes can be made.

  That is, in the above-described second embodiment, the case where the metal material is deposited in the concave groove at the stage of the transfer body has been described, but the present invention is not limited to this, and the stage of creating the polarizer (configuration shown in FIG. 2) As in the second embodiment, the metal material may be deposited in the concave groove.

  In the above-described embodiment, the case where the present invention is applied to the polarizer on the backlight side of the liquid crystal cell has been described. However, the present invention is not limited to this, and a polarizer disposed above and below the liquid crystal layer of the liquid crystal cell ( The present invention may be applied to a linear polarizing plate. In this case, for the polarizer placed on the viewer side (panel surface side) of the liquid crystal cell, the metal linear portion has a three-layer structure, and the upper and lower layers of the material are reflected as compared with the material of the center layer. By using a black material with a low rate, the quality of the display screen can be improved and the visibility and contrast can be improved. Moreover, you may make it apply to the polarizer etc. which comprise the reflection preventing film by a circularly-polarizing plate by lamination | stacking with a quarter wavelength plate.

  In the above-described embodiment, the case where the present invention is applied to an image display device using a liquid crystal display panel has been described. However, the present invention is not limited to this, and for example, antireflection by a circularly polarizing plate is performed by stacking with a quarter-wave plate. The present invention can be widely applied to image display devices other than liquid crystal display panels by applying to polarizers constituting films.

  In the above-described embodiment, the case where the polarizer according to the present invention is applied to an image display device has been described. However, the present invention is not limited thereto, and is widely applied to, for example, an ultraviolet exposure device using linearly polarized light, a projector, and various optical devices. Can be applied.

DESCRIPTION OF SYMBOLS 1 Image display apparatus 2 Liquid crystal display panel 3 Backlight 4, 54 Polarizer 5 Liquid crystal cell 6, 7 Linearly polarizing plate 11, 51 Metal linear part 12, 57 Concave groove 13 Polarizer layer 14, 55 Transfer film 16 Holding part 17 Base material 20A, 20B Metal material 22 Convex strips 25, 56 Support base material 26 Molding resin layer 27 Adhesion strengthening layer 30 Roll plate 35, 36 Winding body 41 Base material 42 Byte

Claims (16)

In a polarizer that limits the transmission of incident electromagnetic waves according to the plane of polarization,
A metal linear part is repeatedly produced with a pitch and a line width less than the shortest wavelength of a wavelength band that restricts transmission,
A holding part of the metal linear part provided with an uneven surface by a plurality of concave grooves is formed,
The metal linear portion is
A polarizer comprising a teardrop-shaped portion formed in a cross-sectional teardrop shape on the bottom surface of the concave groove. The holding part is
The polarizer of Claim 1. It is a transparent resin layer and was hold | maintained on the surface of the base material by a transparent film material. The polarizer according to claim 1, wherein the metal linear portion is formed by a portion having a rectangular cross-section related to the concave groove and a portion having the teardrop shape. An image display apparatus comprising the polarizer according to any one of claims 1, 2, and 3. In the transfer body of the polarizer relating to the wire grid type polarizer,
An uneven surface with a plurality of ridges is formed on the surface of the substrate,
At the top of the ridges of the concavo-convex surface, a metal linear part is produced by a teardrop shape in cross section
A polarizer transfer body having a holding portion for holding the metal linear portion. A shaping resin layer is provided on the surface of the substrate,
The polarizer transfer body according to claim 5, wherein the concavo-convex surface is produced by a molding treatment of the molding resin layer. The uneven surface is provided with an adhesion enhancing layer,
7. The polarizer transfer body according to claim 5, wherein the metal linear portion is disposed on a top portion of the ridge through the adhesion reinforcing layer. 8. An image display device in which the metal linear portion and the holding portion are transferred and held by the polarizer transfer body according to any one of claims 5, 6, and 7. In the transfer body of the polarizer relating to the wire grid type polarizer,
A metal linear part is repeatedly produced with a pitch and a line width less than the shortest wavelength of a wavelength band that restricts transmission,
A holding part of the metal linear part provided with an uneven surface by a plurality of concave grooves is formed,
The metal linear portion is
A transfer body of a polarizer, comprising a teardrop-shaped portion formed in a cross-sectional teardrop shape on the bottom surface of the concave groove. The holding part is
The polarizer transfer body according to claim 9, which is a transparent resin layer and is held on a surface of a support substrate made of a transparent film material. 11. The polarizer transfer body according to claim 9, wherein the metal linear portion is formed by a portion having a rectangular cross-section related to the concave groove and a portion having the teardrop shape. An image display device in which the metal linear portion and the holding portion are transferred and held by the polarizer transfer body according to any one of claims 9, 10, and 11. In the method for manufacturing a polarizer according to a wire grid polarizer,
A process of producing a transfer body for producing a transfer body;
A polarizer production step of producing a polarizer from the transfer body by a transfer method,
The production process of the transfer body includes:
An uneven surface preparation step for preparing an uneven surface with a plurality of protrusions on the surface of the support substrate,
A metal material deposition step of depositing a metal material on the uneven surface;
Etching the metal material deposited on the concavo-convex surface to produce a metal linear portion having a cross-sectional teardrop shape at the top of the ridge, and
A holding part preparation step of preparing the transfer body by applying a transparent resin material to the metal linear part to prepare a holding part for holding the metal linear part,
The polarizer production process includes:
A method of manufacturing a polarizer, comprising: a transfer step of transferring the metal linear portion and the holding portion from the transfer body and peeling the support base material integrally with the uneven surface. The production process of the polarizer,
The polarized light according to claim 13, further comprising: a metal material arranging step of arranging a metal material in a concave groove corresponding to the convex stripe formed on the holding portion by peeling the support base material by the transfer step. Child manufacturing method. In the method of manufacturing a polarizer transfer body according to a wire grid polarizer,
An uneven surface preparation step of forming an uneven surface with a plurality of protrusions on the surface of the first support substrate;
A metal material deposition step of depositing a metal material on the uneven surface;
Etching the metal material deposited on the concavo-convex surface to produce a metal linear portion having a cross-sectional teardrop shape at the top of the ridge, and
The manufacturing method of the transfer body of a polarizer provided with the holding | maintenance part preparation process which applies the transparent resin material to the said metal linear part, and produces the holding | maintenance part which hold | maintains the said metal linear part. A transfer step of laminating the holding portion on a second support substrate and peeling the first support substrate integrally with the uneven surface;
16. A metal material disposing step of disposing the metal material in a concave groove corresponding to the convex strip formed on the holding portion by peeling the first support base material by the transfer step. A process for producing a polarizer transfer body as described in 1 above.

Images