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JP3905661B2 - Method for manufacturing surface light source element - Google Patents

Method for manufacturing surface light source element 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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Japan
Prior art keywords
light
control sheet
light guide
light source
exit
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Expired - Fee Related
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JP04810699A
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JP2000249836A (en
Inventor
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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    • 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
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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[0001]
BACKGROUND OF THE INVENTION
The present invention is a personal computer, a computer monitor, a video camera, a television receiver, a method of manufacturing a surface light source element for use in direct-viewing type liquid crystal display device such as a car navigation system.
[0002]
[Prior art]
A transmissive display device typified by a liquid crystal panel includes a surface light source element (backlight) that emits light in a planar shape and a display panel in which pixels are arranged in a dot shape, and the light of each pixel of the display panel is transmitted. Characters and images are displayed by controlling the transmittance. As a surface light source element, a halogen lamp, a reflector, a lens, etc. are combined to control the luminance distribution of emitted light, a fluorescent tube is provided on the end surface of the light guide, and light from the fluorescent tube is connected to the end surface. The light emitted from a vertical surface, the one provided with a fluorescent tube inside the light guide (direct type), and the like can be mentioned. A surface light source element using a halogen lamp is mainly used in a liquid crystal projector that requires high luminance. On the other hand, since a surface light source element using a light guide can be thinned, it is often used for a direct-view liquid crystal TV, a display of a personal computer, and the like.
[0003]
Surface light source elements used for liquid crystal TVs, notebook personal computers, and the like are required to reduce power consumption and to have high luminance. Realizing high brightness is possible by increasing the number of light sources such as cold cathode fluorescent lamps, but this method is not practical because it leads to an increase in power consumption. In view of this, a surface light source element having a structure in which a sheet (outgoing light control sheet) for extracting light is provided on a light guide plate has been proposed (see Japanese Patent Application Laid-Open No. Hei 8-22213). According to this surface light source element, the total reflection of light is utilized, there is little loss of light, and high brightness can be realized.
[0004]
[Problems to be solved by the invention]
By the way, in the surface light source element of this structure, you have to adhere | attach the light guide plate and the convex part front-end | tip of an emitted light control sheet so that a light beam can pass. As an adhesion method at this time, adhesion using a transparent pressure-sensitive adhesive, thermosetting resin, or the like can be mentioned. However, even if a thin adhesive layer is provided, it is difficult to uniformly apply, and the adhesive layer is thick. When the portion is formed, there is a problem that the minute convex portion of the outgoing light control sheet is buried in the adhesive layer. In this surface light source element, since the minute convex portion is surrounded by air, total reflection occurs on the convex portion wall surface, and this convex portion serves as a condensing lens. If most of the part is buried in the adhesive, it does not function as a condenser lens.
[0005]
The present invention has been made in view of the above problems, and is a surface light source in which an output light control sheet provided with a convex portion that collects light using total reflection is disposed on an output surface of a light guide plate. An object of the present invention is to provide a surface light source element in which only a tip is bonded without burying a minute convex portion of an emitted light control sheet in an adhesive layer, and a manufacturing method thereof.
[0006]
[Means for Solving the Problems]
The surface light source element of the present invention that solves the above problems includes a light source, a reflector, a light guide that receives light from the light source reflected by the reflector, and a surface that faces the exit surface of the light guide. An output light control sheet that is provided on the light exit surface side of the light guide and directs light from the light output surface of the light guide in the front direction. The tip of the convex portion and the light exit surface of the light guide are bonded with an ultraviolet curable resin. This surface light source element is obtained by applying a weak ultraviolet ray in advance to a UV curable resin used for adhesion between the convex portion of the outgoing light control sheet and the outgoing surface of the light guide to make a semi-cured state, and then controlling the outgoing light. The sheet and the exit surface of the light guide are overlapped, and then the ultraviolet curable resin is completely cured by applying strong ultraviolet rays to the ultraviolet curable resin, thereby leading to the leading end of the convex portion of the emitted light control sheet. It can be manufactured by bonding the light emitting surface of the light body.
[0007]
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a schematic configuration diagram of an example of a surface light source element of the present invention. This surface light source element includes a light guide 3 provided with light sources 2 on both end faces 1 and an outgoing light control sheet 4 for controlling the angular distribution of light emitted from the light guide 3. The outgoing light control sheet 4 is disposed on the light guide 3, and light incident on the incident surface 5 is emitted from the outgoing surface 6. A large number of convex portions 7 are formed on the incident surface 5 of the outgoing light control sheet 4, and an adhesive 8 in which the light guide side tip of the convex portion 7 and the light outgoing surface of the light guide 3 are made of an ultraviolet curable resin. It is optically point-bonded so that the light beam passes through it. Around the light source 2, there is provided a reflector 9 that reflects light traveling in a direction opposite to the end surface of the light guide 3 and proceeds in the direction of the end surface of the light guide 3. Light incident on the light guide from the end face 1 propagates through the light guide while repeating total reflection. This propagating light is taken into the outgoing light control sheet 4 from a close contact portion between the convex portion 7 and the outgoing surface of the light guide 3. Thereby, the light propagating in the light guide 3 is sequentially extracted from the contact portion to the outgoing light control sheet 4, and the extracted light is condensed while being totally reflected in the convex portion 7 of the outgoing light control sheet 4. Is done.
[0008]
In the surface light source element of the present invention, an ultraviolet curable resin is used to bond only the tip of the convex portion of the outgoing light control sheet. This surface light source element can be manufactured, for example, by the following method. First, an ultraviolet curable resin is applied to one side of a PET film (for example, 125 μm thick) with a bar coater to a thickness of about 10 μm, and the ultraviolet curable resin surface and a light guide plate made of an acrylic resin or the like are used with a laminator. to paste together. Next, weak ultraviolet rays generated from a high-pressure mercury lamp are irradiated from the PET film side (for example, 120 mJ) to obtain a semi-cured ultraviolet curable resin layer. Thereby, it can prevent that a convex part is embed | buried in an ultraviolet curable resin layer, and can make only the front-end | tip of this convex part point-bond. Then, the PET film is peeled off to obtain a state where an adhesive is applied on the light guide plate. The outgoing light control sheet is pressed from above (for example, pressure 0.3 kgf / cm 2 ) and pasted using a laminator. Finally, the ultraviolet light emitted from the high-pressure mercury lamp is irradiated from the outgoing light control sheet side (for example, 2.0 J) to completely cure the ultraviolet curable resin.
[0009]
The area of the portion where the convex portion of the outgoing light control film is embedded in the ultraviolet curable resin can be measured by observing from the light guide plate side using an optical microscope. The embedded part is observed as a dark part because light does not reflect, and the adhesive surface where the convex part is not embedded is observed as a bright part ((a) in FIG. (B) shows a state in which the convex part is bonded with dots, and (b) shows a state in which the convex part is excessively buried). If the convex part of the outgoing light control sheet is buried in the UV curable resin, the area of the dark part increases, so the state of adhesion is measured by measuring the diameter of the dark part (hereinafter referred to as “adhesion diameter”). Can be judged.
[0010]
FIG. 3 shows an example of the relationship between the irradiation amount of weak ultraviolet rays and the adhesion diameter for obtaining a semi-cured ultraviolet curable resin layer. When the irradiation amount of ultraviolet rays is small, it can be seen that the adhesion diameter increases and the convex portions of the outgoing light control sheet are buried in the ultraviolet curable resin. It can be seen that as the irradiation amount gradually increases, the bonding diameter decreases, and the amount of burying of the convex portion can be controlled so that the emission light characteristic from the emission light control sheet is in a favorable range (of the emission light control sheet). In one example, the adhesion diameter may be in the range of 15 to 18 μm). In addition, since an adhesive force will fall if an irradiation amount becomes large too much, it is preferable to select the irradiation amount as small as possible in the range which a convex part does not embed. Since the irradiation amount varies depending on the concentration of the polymerization initiator contained in the adhesive, it is necessary to select an irradiation amount suitable for the adhesive.
[0011]
The convex portions on the surface of the outgoing light control sheet can be formed by a hot press method, a 2P method by ultraviolet curing, a 2P method by thermal curing, an injection molding method using a female mold, or the like. The stamper used for the production of the outgoing light control sheet is, for example, coating a negative or positive ultraviolet curable resin on a glass substrate, exposing the ultraviolet curable resin through a photomask, and performing electroforming after development. Can be produced. The outgoing light control sheet does not need to be in the form of a sheet, and may be in the form of a plate. Since both the sheet form and the plate form are rich in mass productivity, they can be manufactured in large quantities at a low cost. In the present invention, as the light guide, for example, an acrylic plate having a thickness of about 2 to 20 mm and a distance between the end surfaces of the light guides on which the light sources are arranged, for example, in the range of 50 to 500 mm can be used (guided). (An example of the size of the light body is a width of 340 mm, a length (distance between light sources) of 280 mm, and a thickness of 8 mm). Examples of the resin used for forming the light guide include those having excellent transparency such as polycarbonate resin and polystyrene resin in addition to the acrylic resin.
[0012]
A liquid crystal panel such as STN, TFT, or MINI can be used as the transmissive display element provided on the emission surface using the surface light source element described above as a backlight.
[0013]
【The invention's effect】
According to the present invention, in the surface light source element in which the output light control sheet provided with the convex portion for condensing light using total reflection is disposed on the output surface of the light guide plate, the output light control sheet has a minute size. It is possible to provide a surface light source element in which only the tip is bonded without burying the convex portion in the adhesive layer, and a method for manufacturing the same.
[Brief description of the drawings]
FIG. 1 is a schematic configuration diagram of a surface light source element of the present invention.
FIG. 2 is a view showing an image of an adhesive portion between a convex portion of an outgoing light control sheet and a light guide.
FIG. 3 is a diagram illustrating an example of a relationship between an irradiation amount of ultraviolet rays and an adhesion diameter.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Light guide end surface 2 ... Light source 3 ... Light guide 4 ... Output light control sheet 5 ... Output light control sheet entrance surface 6 ... Output light control sheet exit surface 7 ... Convex part 8 ... Adhesive 9 made of ultraviolet curable resin ... reflector

Claims (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。A light source, a reflector, a light guide that receives light from the light source reflected by the reflector from an end surface, and a plurality of convex portions on a surface facing the light exit surface of the light guide. An emission light control sheet that is provided on the surface side and directs light from the emission surface of the light guide to the front direction, and the tip of the convex portion of the emission light control sheet and the emission surface of the light guide are ultraviolet rays the method of manufacturing a bonded have that the surface light source device with a cured resin, by applying a pre-weak UV ultraviolet curing resin used for bonding the exit surface of the distal end portion and the light guide body of the convex portion of the emitted light control sheet After being in a semi-cured state, the exit light control sheet and the exit surface of the light guide are overlapped, and then the UV curable resin is completely cured by irradiating the UV curable resin with strong UV light, thereby allowing the exit light to exit. The tip of the projection of the light emission control sheet and Method of manufacturing the surface light source device characterized by bonding the exit surface of the light body.
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