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JP3905661B2 - 面光源素子の製造方法 - Google Patents

面光源素子の製造方法 Download PDF

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Publication number
JP3905661B2
JP3905661B2 JP04810699A JP4810699A JP3905661B2 JP 3905661 B2 JP3905661 B2 JP 3905661B2 JP 04810699 A JP04810699 A JP 04810699A JP 4810699 A JP4810699 A JP 4810699A JP 3905661 B2 JP3905661 B2 JP 3905661B2
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light
control sheet
light guide
light source
exit
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JP2000249836A (ja
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洋一 橋本
克也 藤澤
陸司 渡辺
伊久雄 大西
慎二 平松
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Kuraray Co Ltd
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Kuraray Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1403—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
    • B29C65/1406—Ultraviolet [UV] radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C65/1435—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface at least passing through one of the parts to be joined, i.e. transmission welding
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    • B29C65/1464—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the way of heating the interface making use of several radiators
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1487—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation making use of light guides
    • B29C65/149—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation making use of light guides being a part of the joined article
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
    • B29C65/4845—Radiation curing adhesives, e.g. UV light curing adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
    • B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
    • B29C66/9161—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux
    • B29C66/91641—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux the heat or the thermal flux being non-constant over time
    • B29C66/91643—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux the heat or the thermal flux being non-constant over time following a heat-time profile
    • B29C66/91645—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux the heat or the thermal flux being non-constant over time following a heat-time profile by steps
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
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Description

【０００１】
【発明の属する技術分野】
本発明は、パーソナルコンピュータ、コンピュータ用モニタ、ビデオカメラ、テレビ受信機、カーナビゲーションシステムなどの直視型液晶表示装置に用いられる面光源素子の製造方法に関する。
【０００２】
【従来の技術】
液晶パネルに代表される透過型表示装置は、面状に光を発する面光源素子（バックライト）とドット状に画素が配置された表示パネルとで構成され、該表示パネルの各画素の光の透過率がコントロールされることによって文字および映像が表示される。面光源素子としては、ハロゲンランプ、反射板、レンズ等が組み合わされて出射光の輝度の分布が制御されるもの、蛍光管が導光体の端面に設けられ、蛍光管からの光が端面と垂直な面から出射されるもの、蛍光管が導光体の内部に設けられたもの（直下型）などが挙げられる。ハロゲンランプを利用した面光源素子は、高輝度を必要とする液晶プロジェクタに主に用いられる。一方、導光体を利用した面光源素子は薄型化が可能であるため、直視型の液晶ＴＶ、パーソナルコンピュータのディスプレイなどに用いられることが多い。
【０００３】
液晶ＴＶ、ノートパソコンなどに用いられる面光源素子では、消費電力を軽減すること、および高輝度であることが要求されている。高輝度化を実現することは、冷陰極管などの光源を増やすことで可能であるが、この方法は消費電力の増加につながるため実用的ではない。そこで、導光板上に光を取り出すシート（出射光制御シート）が設けられた構成の面光源素子が提案されている（特開平８−２２１０１３号公報等を参照）。この面光源素子によれば、光の全反射を利用しており、光の損失が少なく、高輝度化を実現することができる。
【０００４】
【発明が解決しようとする課題】
ところで、この構成の面光源素子では、導光板と出射光制御シートの凸部先端とを光線が通過可能なように接着しなければならない。このときの接着方法としては、透明な粘着剤、熱硬化樹脂などを用いて接着することが挙げられるが、薄い接着層を設けようとしても均一に塗布することが困難であり、接着層に厚い部分ができると、出射光制御シートの微小な凸部が接着層に埋まってしまうという課題が生じていた。この面光源素子においては、当該微小な凸部が周囲を空気で囲まれていることによって凸部壁面で全反射が生じ、これにより該凸部が集光レンズの役割を果たすのであり、該凸部の大部分が接着剤に埋まってしまうと集光レンズの役割を果たさなくなる。
【０００５】
本発明は、上記の課題に鑑みてなされたものであり、全反射を利用して光を集光する凸部が設けられた出射光制御シートが導光板の出射面上に配置される面光源素子において、出射光制御シートの微小な凸部を接着層に埋没させることなく先端のみが接着された面光源素子およびその製造方法を提供することを目的とする。
【０００６】
【課題を解決するための手段】
上記の課題を解決する本発明の面光源素子は、光源と、リフレクタと、リフレクタで反射された光源からの光が端面から入射される導光体と、導光体の出射面に対向する面に複数の凸部を有し、導光体の出射面側に設けられて、導光体の出射面からの光を正面方向に向かわせる出射光制御シートとを備え、該出射光制御シートの凸部の先端部と導光体の出射面とが紫外線硬化樹脂により接着されていることを特徴とする。この面光源素子は、出射光制御シートの凸部の先端部と導光体の出射面との接着に用いる紫外線硬化樹脂にあらかじめ微弱な紫外線を当てて半硬化状態にした後、該出射光制御シートと導光体の出射面とを重ね合わせ、次いで、該紫外線硬化樹脂に強力な紫外線を当てることにより紫外線硬化樹脂を完全硬化させることによって、該出射光制御シートの凸部の先端部と導光体の出射面とを接着することにより製造することができる。
【０００７】
【発明の実施の形態】
図１に本発明の面光源素子の１例の概略構成図を示す。この面光源素子は両端面１に光源２が設けられた導光体３と、導光体３から出射された光の角度分布を制御する出射光制御シート４とを備えている。出射光制御シート４は導光体３上に配置されており、入射面５に入射した光が出射面６から出射される。出射光制御シート４の入射面５には多数の凸部７が形成されており、この凸部７の導光体側先端と導光体３の光出射面とが紫外線硬化樹脂からなる接着剤８を用いて光線が通過するように光学的に点接着されている。光源２の周りには、導光体３の端面とは反対方向に進む光を反射し、導光体３の端面方向に進行させるリフレクタ９が設けられている。端面１から導光体に入射した光は導光体内を全反射を繰り返しながら伝搬していく。この伝搬光は凸部７と導光体３の出射面との密着部から出射光制御シート４に取り込まれる。これにより、導光体３内を伝搬する光は当該密着部から順次、出射光制御シート４に取り出され、取り出された光は出射光制御シート４の凸部７内で全反射されながら集光される。
【０００８】
本発明の面光源素子では出射光制御シートの凸部の先端のみを接着するために紫外線硬化樹脂を用いる。この面光源素子は、例えば、以下の方法により製造することができる。まず、ＰＥＴフィルム（例えば、厚さが１２５μｍ）の片側にバーコーターで紫外線硬化樹脂を約１０μｍの厚さになるように塗布し、紫外線硬化樹脂面とアクリル樹脂製等の導光板とをラミネーターで貼り合わせる。次いで、高圧水銀ランプから発生される微弱な紫外線をＰＥＴフィルム側から照射し（例えば１２０ｍＪ）、半硬化状態の紫外線硬化樹脂層を得る。これにより、凸部が紫外線硬化樹脂層に埋没することを防ぎ、該凸部の先端のみを点接着させることができる。そして、ＰＥＴフィルムを剥離して導光板の上に接着剤が塗布された状態を得る。その上から出射光制御シートを押しつけ（例えば、圧力０．３ｋｇｆ／ｃｍ2）、ラミネーターを用いて貼り付ける。最後に出射光制御シート側から高圧水銀ランプから発せられる紫外線を照射し（例えば２．０Ｊ）、紫外線硬化樹脂を完全に硬化する。
【０００９】
出射光制御フィルムの凸部が紫外線硬化樹脂内に埋め込まれた部分の面積は、導光板側から光学顕微鏡を用いて観察することにより測定することができる。埋め込まれた部分は光が反射してこないために暗い部分として観察され、凸部が埋め込まれていない接着剤表面は明るい部分として観察される（図２において（ａ）は紫外線硬化樹脂が適度に半硬化されており、凸部が点で接着されている状態を、（ｂ）は紫外線硬化樹脂の硬化が不十分で、凸部が過度に埋没している状態を示す。）。出射光制御シートの凸部が紫外線硬化樹脂に埋没すれば暗い部分の面積が大きくなるので、暗い部分の直径（以下、これを「接着直径」と表現する。）を測定することによって接着の状態を判断することができる。
【００１０】
半硬化状態の紫外線硬化樹脂層を得るための微弱な紫外線の照射量と接着直径との関係の一例を図３に示す。紫外線の照射量が少ないと、接着直径は大きくなり、出射光制御シートの凸部が紫外線硬化樹脂に埋没していることが分かる。照射量が徐々に大きくなるにつれて接着直径が小さくなり、凸部の埋没量が出射光制御シートからの出射光特性が良好な範囲になるように制御することができることが分かる（出射光制御シートの一例では接着直径が１５〜１８μｍの範囲であれば良い。）。なお、照射量が大きくなりすぎると接着力が低下するので、凸部が埋没しない範囲でなるべく少ない照射量を選択することが好ましい。照射量は、接着剤に含まれる重合開始剤濃度などで変化するため、接着剤に適した照射量を選ぶ必要がある。
【００１１】
出射光制御シート表面の凸部は、熱プレス法、紫外線硬化による２Ｐ法、熱硬化による２Ｐ法、雌金型を用いた射出成形法等によって形成することができる。出射光制御シートの作製に用いるスタンパは、例えばガラス基板上にネガ型あるいはポジ型の紫外線硬化樹脂をコーティングし、この紫外線硬化樹脂をフォトマスクを介して露光し、現像後、電鋳を行うことにより作製することができる。出射光制御シートはシート状である必要はなく、板状であってもよい。シート状および板状の何れでも量産性に富むため、安価で大量に製造することが可能である。本発明では、導光体として、例えば厚さが２〜２０ｍｍ程度で、光源が配置された導光体端面間の距離が、例えば５０〜５００ｍｍの範囲にあるアクリル板を用いることができる（導光体のサイズの一例は、幅が３４０ｍｍ、長さ（光源間距離）が２８０ｍｍ、厚さが８ｍｍである。）。導光体の成形に用いる樹脂としては、アクリル樹脂の外にポリカーボネート樹脂、ポリスチレン樹脂等の透明性に優れるものが挙げられる。
【００１２】
上記の通り説明した面光源素子をバックライトとして用い、その出射面に設けられる透過型の表示素子としては、 ＳＴＮ、ＴＦＴ、ＭＩＮＩなどの液晶パネルが挙げられる。
【００１３】
【発明の効果】
本発明によれば、全反射を利用して光を集光する凸部が設けられた出射光制御シートが導光板の出射面上に配置される面光源素子において、出射光制御シートの微小な凸部を接着層に埋没させることなく先端のみが接着された面光源素子およびその製造方法を提供することができる。
【図面の簡単な説明】
【図１】本発明の面光源素子の概略構成図である。
【図２】出射光制御シートの凸部と導光体との接着部分の像を示す図である。
【図３】紫外線の照射量と接着直径との関係の一例を示す図である。
【符号の説明】
１…導光体端面
２…光源
３…導光体
４…出射光制御シート
５…出射光制御シート入射面
６…出射光制御シート出射面
７…凸部
８…紫外線硬化樹脂からなる接着剤
９…リフレクタ

Claims (1)

  1. 光源と、リフレクタと、リフレクタで反射された光源からの光が端面から入射される導光体と、導光体の出射面に対向する面に複数の凸部を有し、導光体の出射面側に設けられて導光体の出射面からの光を正面方向に向かわせる出射光制御シートとを備え、該出射光制御シートの凸部の先端部と導光体の出射面とが紫外線硬化樹脂により接着されている面光源素子の製造方法において、前記出射光制御シートの凸部の先端部と前記導光体の出射面との接着に用いる紫外線硬化樹脂にあらかじめ微弱な紫外線を当てて半硬化状態にした後、該出射光制御シートと導光体の出射面とを重ね合わせ、次いで、該紫外線硬化樹脂に強力な紫外線を当てることにより紫外線硬化樹脂を完全硬化させることによって、該出射光制御シートの凸部の先端部と導光体の出射面とを接着することを特徴とする面光源素子の製造方法。
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