KR101209803B1 - Method for manufacturing one body type optical film and one body type optical film - Google Patents

Abstract

PURPOSE: An integral optical film is provided to have a uniformly set incidence angle of light which is received through a bottom side by forming optical layers to have a flat bottom side without a base layer. CONSTITUTION: A method for manufacturing an integral optical film is as follows: A curable resin is spread on a first mold which has patterns(11). A base layer is placed on a top surface of the resin which is spread on the first mold. Light for a temporarily curing is projected into the resin so that a first temporarily cured layer is formed. The curable resin is spread on a second mold having patterns. A release film is placed on the top surface of the resin spread on the second mold to make the top surface of the resin spread on the second mold flat. Light for a temporarily curing is projected into the resin so that a second temporarily cured layer(2) is formed. The first layer which is separated from the first mold and the base layer are laminated on the second layer. Light is projected into the second layer, the first layer, and the base layer so that the layers are integrated. The second mold is separated so that a double-layered optical film(120) is formed.

Description

Integrated optical film manufacturing method and integrated optical film {METHOD FOR MANUFACTURING ONE BODY TYPE OPTICAL FILM AND ONE BODY TYPE OPTICAL FILM}

The present application relates to an integrated optical film manufacturing method and an integrated optical film, and more particularly, to an integrated optical film manufacturing method that can be applied to a liquid crystal display device, a light receiving display device, a signboard, an illumination, and an integrated optical film manufactured through the same. will be.

Liquid crystal display (LCD) is a representative display device widely used in various fields. Since the liquid crystal display is a non-light emitting device, a backlight unit for generating light is required. Therefore, such a backlight unit is an important factor for determining the size and light efficiency of the liquid crystal display device, and is composed of an assembly of various optical sheets.

In general, the backlight unit includes a light source, a light guide plate, a reflecting plate, a diffusion sheet, a prism sheet, and a protective sheet. In exemplary embodiments, the light generated from the light source is directed toward the diffusion sheet through the light guide plate, and the light diffused by the diffusion sheet is focused through the first and second prism sheets to be directed toward the liquid crystal display panel.

The diffusion sheet serves to provide uniform luminance over the entire area. In addition, the prism sheet performs a function of improving luminance in a specific viewing angle range. The luminance improvement at this particular viewing angle may be realized by condensing by the prism structure.

However, since the diffusion sheet and the prism sheet of the conventional backlight unit are provided by simple contact, the diffusion sheet and the prism sheet may be shifted from each other when the liquid crystal display device is used for a long time. A light leakage phenomenon may occur, or the light may not be properly refracted to the liquid crystal display panel, resulting in a narrow viewing angle or a problem in that the screen cannot be viewed at a specific viewing angle.

In addition, the optical sheets included in the backlight unit may have various patterns for controlling the degree of diffusion or condensing. By the way, in order to stably stack the optical sheets having a pattern without sag of the bottom surface or deformation of the pattern shape, the base layer underlying each of the optical sheets had to be disposed. For example, by forming a diffusion sheet having a pattern on one substrate layer, forming a prism sheet having a pattern on another substrate layer, and then stacking another substrate layer on which the prism sheet is formed on the diffusion sheet. The assembly was prepared.

That is, the conventional backlight unit has a limitation in implementing a slim thickness because the base layer must be disposed on each lower side of the optical sheets, and it is difficult to predict the path of incident light because an additional interface is formed between the base layer and the optical sheet. .

The present application is to solve the above-mentioned problems of the prior art, it is firmly secured to the integrity and provided with a slimmer, at the same time manufacturing an integrated optical film capable of efficiently diffusing or refracting light so as to greatly improve the brightness and light uniformity It is an object to provide a method and an integrated monolithic optical film.

As a technical means for achieving the above technical problem, the integrated optical film manufacturing method according to the first aspect of the present application comprises the steps of (a) coating a curable resin on a first mold having a pattern; (b) covering the substrate layer on an upper surface of the resin coated on the first mold; (c) projecting light for temporary curing onto the resin covered with the base layer to form a first layer in a temporary curing state; (d) coating the curable resin on the second mold having the pattern; (e) covering the release film on the upper surface of the resin coated on the second mold; (f) projecting light for temporary curing onto the release film-covered resin to form a second layer in a temporary curing state; (g) stacking the first layer and the base layer separated from the first mold on the second layer from which the release film is removed such that the first layer contacts the second layer; (h) projecting light onto the second layer, the first layer, and the base layer to integrate the second layer, the first layer, and the base layer and to separate the second mold to form a two-layer optical film; It may include.

In addition, as a technical means for achieving the above technical problem, the integrated optical film manufacturing method according to the second aspect of the present application comprises the steps of (a) coating a curable resin on the first mold having a pattern; (b) covering the substrate layer on an upper surface of the resin coated on the first mold; (c) projecting light for complete curing onto the resin covered with the substrate layer to form a first layer in a fully cured state with the substrate layer; (d) coating the curable resin on the second mold having the pattern; (e) covering the release film on the upper surface of the resin coated on the second mold; (f) fully curing the resin covered with the release film to form a second layer in a fully cured state; (g) coating a tacky or adhesive material on the second layer from which the release film is removed, and contacting the first layer with the first layer and the base layer separated from the first mold; Laminating to ensure that; And (h) separating the second mold to form a two-layer optical film.

In addition, as a technical means for achieving the above technical problem, the integrated optical film manufacturing method according to the third aspect of the present application comprises the steps of (a) coating a curable resin on the first mold having a pattern; (b) covering the substrate layer on an upper surface of the resin coated on the first mold; (c) projecting light for temporary curing onto the resin covered with the base layer to form a first layer in a temporary curing state; (d) coating the curable resin on the second mold having the pattern; (e) covering the release film on the upper surface of the resin coated on the second mold; (f) fully curing the resin covered with the release film to form a second layer in a fully cured state; And (g) coating a tacky or adhesive material on the second layer from which the release film is removed, and separating the first layer and the base layer separated from the first mold to the second layer. Laminating to contact; And (h) projecting light for full cure onto the second layer, the first layer, and the base layer to integrate the second layer, the first layer, and the base layer, and separate the second mold to separate the two-layer optics. Forming a film may be included.

In addition, as a technical means for achieving the above technical problem, the integrated optical film manufacturing method according to the fourth aspect of the present application comprises the steps of (a) coating a curable resin on the first mold having a pattern; (b) covering the substrate layer on an upper surface of the resin coated on the first mold; (c) projecting light for complete curing onto the resin covered with the substrate layer to form a first layer in a fully cured state with the substrate layer; (d) coating the curable resin on the second mold having the pattern; (e) covering the release film on the upper surface of the resin coated on the second mold; (f) projecting light for temporary curing onto the release film-covered resin to form a second layer in a temporary curing state; (g) stacking the first layer and the base layer separated from the first mold on the second layer from which the release film is removed such that the first layer contacts the second layer; And (h) projecting light onto the second layer, the first layer, and the base layer to integrate the second layer, the first layer, and the base layer and to separate the second mold to form a two-layer optical film. It may include a step.

In addition, as a technical means for achieving the above technical problem, the integrated optical film according to the first aspect of the present application is a base layer; A first layer disposed on the substrate layer and having a pattern formed on an upper surface thereof; And a second layer disposed on the first layer and having a pattern formed thereon, wherein the second layer is directly connected to the first layer without the addition of a separate base layer between the first layer. The base layer, the first layer, and the second layer may be integrally formed.

According to the above-described problem solving means of the present application, the optical layers stacked on the first layer can be formed to have a flat bottom surface without a base layer supporting each, having a slim thickness and at the same time incident through the bottom surface An integrated optical film capable of uniformly setting the incident angle of the light to be provided may be provided.

In addition, according to the aforementioned problem solving means of the present application, the optical layers stacked on the first layer can be manufactured and laminated in a state having a clear shape without a base layer, it is possible to easily implement the pattern in a desired shape, Accordingly, an integrated optical film that can more easily adjust or improve luminance and light uniformity may be provided according to application conditions for each product.

In addition, according to the above-described problem solving means of the present application, even if each layer is formed integrally and the use period is prolonged, it does not deviate from each other unless excessive external force exceeding the allowable value, light leakage phenomenon or narrow optical viewing angle or specific The problem that light divergence is not achieved at the viewing angle can be solved.

1 is a flowchart illustrating a process of manufacturing a two-layer optical film through the integrated optical film manufacturing method according to the first embodiment of the present application.
2 is a flowchart illustrating a process of manufacturing a three-layer optical film through the integrated optical film manufacturing method according to the first embodiment of the present application.
3A to 3D, 4A to 4D, 5A, and 5B are cross-sectional views illustrating a method of manufacturing an integrated optical film according to a first embodiment.
6 is a flowchart illustrating a process of manufacturing a two-layer optical film through the integrated optical film manufacturing method according to the second embodiment of the present application.
7A to 7D, 8A to 8E, 9A, and 9B are cross-sectional views illustrating a method of manufacturing an integrated optical film according to a second embodiment.
10 is a flowchart illustrating a process of manufacturing a two-layer optical film through the integrated optical film manufacturing method according to the third embodiment of the present application.
11 is a flowchart illustrating a process of manufacturing a two-layer optical film through the integrated optical film manufacturing method according to the fourth embodiment of the present application.
12 is a perspective view of an integrated optical film according to the first embodiment of the present application.
13 is an exploded perspective view of a unitary optical film according to the first embodiment of the present application.
14A is a plan view from above of a first layer of an integrated optical film according to a first embodiment of the present disclosure;
14B is a plan view from above of another example of the first layer of the integrated optical film according to the first embodiment of the present application;
15 is a perspective view of an integrated optical film according to a second embodiment of the present application.
16 is a perspective view of an integrated optical film according to a third embodiment of the present application.
17 is a perspective view of an integrated optical film according to a fourth embodiment of the present application.
18 is a perspective view of an integrated optical film according to a fifth embodiment of the present application.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those skilled in the art can easily carry out the present invention. It should be understood, however, that the present invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. In the drawings, the same reference numbers are used throughout the specification to refer to the same or like parts.

Throughout this specification, when a part is referred to as being "connected" to another part, it is not limited to a case where it is "directly connected" but also includes the case where it is "electrically connected" do.

Throughout this specification, when a member is " on " another member, it includes not only when the member is in contact with the other member, but also when there is another member between the two members.

Throughout this specification, when an element is referred to as "including " an element, it is understood that the element may include other elements as well, without departing from the other elements unless specifically stated otherwise. The terms "about "," substantially ", etc. used to the extent that they are used throughout the specification are intended to be taken to mean the approximation of the manufacturing and material tolerances inherent in the stated sense, Accurate or absolute numbers are used to help prevent unauthorized exploitation by unauthorized intruders of the referenced disclosure. As used throughout this specification, the term "step to" or "step of" does not mean "step for."

Throughout this specification, the term “combination of these” included in the expression of the makushi form means one or more mixtures or combinations selected from the group consisting of the constituents described in the expression of the makushi form, wherein the constituents It means to include one or more selected from the group consisting of.

For reference, terms related to directions or positions (top, bottom, top, upward, downward, etc.) in the description of the embodiments of the present disclosure are based on FIGS. 3A to 3D, 4A to 4D, 5A, and 5B. It is set. For example, in FIG. 5B, the upward direction may be upward, the upward direction may be the upper surface, the downward direction may be downward, and the downward direction may be the lower surface. However, in various practical applications of the embodiments of the present disclosure, the upper surface may be disposed in various directions such as to face forward.

Hereinafter, a method of manufacturing an integrated optical film according to various embodiments of the present disclosure will be described.

First, the integrated optical film manufacturing method (hereinafter, referred to as a 'first integrated optical film manufacturing method') according to the first embodiment of the present application will be described.

FIG. 1 is a flowchart illustrating a process of manufacturing a two-layer optical film through the integrated optical film manufacturing method according to the first embodiment of the present application, and FIG. 2 is a flowchart illustrating the integrated optical film manufacturing method according to the first embodiment of the present application. It is a flowchart which shows the process of manufacturing a layer optical film. 3A to 3D, 4A to 4D, 5A, and 5B are cross-sectional views illustrating a method of manufacturing an integrated optical film according to a first embodiment.

1 and 3A, the first integrated optical film manufacturing method S100 includes coating the curable resin on the first mold 600 having the pattern 610 (S105).

Referring to FIG. 3A, the pattern 610 of the first mold 600 may be variously formed to correspond to the shape of the pattern 11 of the first layer 1. For example, as illustrated in FIG. 3A, the pattern 610 of the first mold 600 may be convex, and the pattern 11 of the first layer 1 may be concave to engage with it. For reference, as shown in FIG. 18, when the pattern of the first layer 1 is convex, the pattern 610 of the first mold 600 may be concave to correspond thereto.

1 and 3B, the first integrated optical film manufacturing method S100 includes covering the base layer 9 on the top surface of the resin coated on the first mold 600 (S110).

The base material layer 9 is the most basic layer of each layer which forms an integrated optical film. Referring to FIG. 5B, the base layer 9 may be a layer that transmits light from the lower side to the first layer 1.

Referring to FIG. 3B, in step S110, the base layer 9 is disposed above the resin corresponding to the first layer 1. That is, the base layer 9 covers the upper surface of the resin to be the first layer 1 so as to be temporarily cured or completely cured in a state where the upper surface of the resin is kept flat during future curing or complete curing.

For example, the base layer 9 may be a flat film shape made of a material such as polyethylene terephthalate (PET), polycarbonate (PC), polyethylene (PE), but is not limited thereto. That is, the base layer 9 may be formed of a material having a predetermined refractive index and light transmittance in order to secure desired luminance and light uniformity.

In addition, a light guide plate (LGP) may serve as the base layer 9. In other words, the substrate layer 9 may be a light guide plate. The light guide plate is a component that converts light incident from a lamp (not shown) into uniform planar light, and is generally made of PMMA (polymethymethacrylate), which is an acrylic resin. Thus, the backlight unit to which the integrated optical film is applied, in which the base layer 9 itself becomes a light guide plate, may be provided more slim.

However, the base layer 9 is not necessarily limited to the light guide plate, and it is preferable that the base layer 9 is understood as a concept that includes all the layers capable of transmitting light from the lower side to the first layer 1 as the bases of the respective layers. Do.

1 and 3C, in a method of manufacturing a first integrated optical film S100, light for temporary curing is projected onto a resin covered with a base layer 9 to form a first layer 1 in a temporary curing state. It includes a step (S115).

Here, the resin may be a curable transparent resin cured by any one of ultraviolet (UV) and infrared (IR). For example, the light projected onto the resin for the temporary curing may be short wavelength ultraviolet (UV), and the short wavelength ultraviolet light may be realized through a BL lamp.

For reference, the light projected onto the resin for complete curing may be long wavelength ultraviolet (UV) light, and may be implemented through a mercury lamp, a metal halide lamp, a gallium lamp, an LED lamp, and the like. Such long wavelength ultraviolet (UV) may involve not only photo curing but also thermal curing.

Also, projecting light for temporary curing on the resin means that the resin projects light enough to be temporarily cured. For example, as shown in FIG. 3C, the light for temporary curing may be simultaneously projected from the upper side and the lower side, but the present invention is not limited thereto, and light projection for temporary curing may be performed in another manner as necessary.

Here, to describe in more detail how hard curing means, the resin is coated on the first mold 600, and then cured to a predetermined or more to prepare the first layer 1 in an excessively hardened state. When the first layer 1 is entangled in the first mold 600, it becomes difficult to separate the first layer 1 from the first mold 600, or the first layer 1 is formed in the first mold 600. ) May damage the surface.

That is, the temporary hardening is such that the first layer 1 can be easily separated from the first mold 600 without damage, and the first layer 1 after the first layer 1 is separated from the first mold 600. It means curing made to the extent that the shape of 1) can be maintained without deformation. The term temporary curing used in the future may also be used in the same sense as described above.

However, when the first mold 600 is provided through a mold having a surface having a high releasability through a release agent or the like rather than a general mold, the first mold even after the first layer 1 is completely cured. It may be separated from the (600) without damage. However, in order to form the first layer 1 having a more stable and clear pattern, it will be preferable to perform the temporary curing as described above.

Referring also to FIG. 3D, the first layer 1 in this temporary hardened state and the base layer 9 integrally bonded with the temporary hardened first layer 1 may be separated from the first mold 600. have. However, this separation point is not necessarily before the second layer 2 is manufactured, and the separation point may be determined in consideration of the manufacturing conditions. In a similar context, the manufacturing process of the first layer 1 does not necessarily have to proceed first, and the manufacturing process of the second layer 2 may proceed first depending on the manufacturing conditions.

1 and 4A, the first integrated optical film manufacturing method S100 may include coating a curable resin on a second mold 700 having a pattern 710 (S120).

Referring to FIG. 4A, the pattern 710 of the second mold 700 may be variously formed to correspond to the shape of the pattern 21 of the second layer 2. For example, as illustrated in FIG. 4A, the pattern 710 of the second mold 700 may have a prism shape, and the pattern 11 of the first layer 1 may have a prism shape that engages thereto. For reference, as shown in FIG. 17, if the pattern of the second layer 2 is convex, on the contrary, the pattern 710 of the second mold 700 may be formed to be concave to correspond thereto.

Also, referring to FIGS. 1 and 4B, the first integrated optical film manufacturing method S100 includes covering the release film 99 on the top surface of the resin coated on the second mold 700 (S125).

The release film 99 refers to a film having a release property. In other words, the release film 99 is a film made of a material having easy peelability. For example, the release film 99 may have a surface material including silica, fluorine, titanium, or the like. The release film 99 may be separated from the cured or fully cured resin even after the resin is temporarily cured or completely cured, unlike the base layer 9 in the salping step S110.

Referring to FIG. 3B, in step S125, the release film 99 is disposed on the upper side of the resin corresponding to the second layer 2. That is, the release film 99 covers the upper surface of the resin to be the second layer 2 so that the upper surface of the resin may be temporarily cured or completely cured in a state where the upper surface of the resin is kept flat in the future.

1 and 4C, the first integrated optical film manufacturing method S100 may project light for temporary curing onto a resin covered with a release film 99 to form a second layer 2 in a temporary curing state. It includes a step (S130). The description of the material of the resin, temporary curing, light for temporary curing, etc. will be omitted because it is overlapped with the description in step S115.

1 and 4D, the first integrated optical film manufacturing method S100 may include the first layer 1 separated from the first mold 600 on the second layer 2 from which the release film 99 is removed. ) And stacking the base layer 9 so that the first layer 1 is in contact with the second layer 2 (S135).

That is, the resin is temporarily cured to cover the release film 99 to the extent that the flat upper surface (lower surface when viewed in FIG. 5B) can be maintained without deformation to form the second layer 2, and then the release film as shown in FIG. 4D. The first layer 1 and the base layer 9 separated from the second mold 600 are laminated on the second layer 2 from which the 99 is removed, as shown in FIG. 3D.

1, 5A, and 5B, a method of manufacturing a first integrated optical film S100 may be performed by projecting light onto a second layer 2, a first layer 1, and a base layer 9. Integrating the two layers 2, the first layer 1, and the base layer 9, and separating the second mold 700 to form the two-layer optical film 120 (S140).

In this case, the light projected in step S140 may be light for complete curing. When the light for the complete curing is projected in step S140, the second layer (2) and the first layer in a state that the second layer (2), the first layer (1), and the base layer (9) are bonded to each other Since (1) is completely cured, the two-layer optical film 120 can be made of an integral optical film having integrity. That is, as the first layer 1 and the second layer 2 are completely cured, the bonded portions of the second layer 2, the first layer 1, and the base layer 9 are entangled with each other to form an integrated optical body. A film can be formed.

For reference, the integral means that the laminated layers are formed as one body so that each layer is not separated from each other when an external force is applied to the optical film.

As described above, the two-layer optical film 120 is integrally formed, so that the second layer 2, the first layer 1, and the base layer 9 are not provided with excessive external force exceeding the allowable value even if the service life becomes longer. ) Does not deviate from each other, so that a light leakage phenomenon, a narrow viewing angle, or a light divergence at a specific viewing angle may be solved.

In addition, since each layer is integrated by itself through complete curing, there is no need to add a separate adhesive layer or adhesive layer, the integrated optical film can be provided more slim. In addition, since there is no addition of an adhesive layer or an adhesive layer, the configuration is simple, so that the manufacturing is easy and the composition is not coarse, so that the bonding between the components is more firm, and separation between the laminated layers can be more surely prevented.

In addition, the first layer 1 and the second layer 2 may be made of a resin that is tacky or adhesive. That is, the first layer 1 and the second layer 2 are formed by completely curing the resin made of a tacky or adhesive material, thereby making it possible to manufacture a more rigid integrated optical film.

For reference, the term "adhesiveness" means a property in which adhesive force is continuously maintained by sticking sticky. For example, adhesiveness is a property that stickiness is continuously maintained on the surface of the first layer 1 adhering to the base material layer 9 even if the first layer 1 applied to the base layer 9 is removed by applying a predetermined force or more. . In other words, when the first layer 1 having the adhesive property is removed from the base layer 9 and then adhered to the base layer 9 again, the first layer 1 may be stuck to each other again to maintain a predetermined or more integrity.

That is, adhesiveness is a concept that is distinguished from adhesiveness, which is a property in which stickiness exists only at the time of initial bonding and stickiness is lost when it is detached and cannot be reattached. In other words, the concept of adhesion refers to adhesion, adhesion, etc., in which an adhesive force exists only when the integrated optical film is first manufactured, and when the layers are separated from each other by an unexpected external force after the completion of manufacturing, the adhesion is lost and cannot be bonded again. Can be understood as another concept.

As such, by allowing each layer to be formed through a sticky resin, the surface of each layer may be unexpectedly generated even when an external force of a size and direction exceeding the allowable value is applied to the finished monolithic optical film so that the layers are separated from each other. Since stickiness is constantly maintained, the separated layers can be easily integrated again. Therefore, the integrated optical film can be more firmly maintained, thereby solving the problem that light leakage occurs, the optical viewing angle is narrowed, or the light does not diverge to a specific viewing angle.

In this case, when it is made of a two-layer optical film 120 (see FIG. 5B) in which the first layer 1 and the second layer 2 are laminated on the base layer 9 through complete curing, Unlike the first layer 1, which is separated from the first mold 600, the second layer 2 is separated from the second mold 700 after being fully cured. Therefore, the second mold 700 is preferably provided through a mold having a high surface releasability (peelability), through which the second layer 2 is stably separated from the second mold 700 in step S140. Can be.

In addition, referring to FIG. 5B, the first integrated optical film manufacturing method S100 may include a second mold 700, a second layer 2, and a first layer between the rolls 900 installed at intervals before the step S140. 1), and further comprising the step of passing through the substrate layer (9). In this case, the interval between the rolls 900 may be smaller than or equal to the total thickness of the second mold 600, the second layer 2, the first layer 1, and the base layer 9.

As described above, prior to the progress of the step S140, the second mold 700, the second layer 2, the first layer 1, and the substrate layer 9, which are sequentially stacked, are first passed through the roll 900. Physical action may be taken to make the overall thickness uniform. In addition, predetermined compression may be achieved by adjusting the gap between the rolls 900.

In this case, as shown in FIG. 5B, the second layer 2 and the first layer 1 are supported by the second mold 700 on the lower side and protected by the substrate layer 9 on the upper side. Accordingly, since the second layer 2 and the first layer 1 are indirectly subjected to a physical force for uniform thickness or predetermined compression, more stable passage can be achieved.

Meanwhile, referring to FIGS. 2 and 15, the method of manufacturing a first integrated optical film S100 may include coating curable resin on a third mold having a pattern after step S140 (S145), and coating on the third mold. Covering the release film on the upper surface of the resin (S150), the step of forming a third layer (3) of the temporary curing state by projecting light for temporary curing on the resin covered with the release film (S155), removing the release film Stacking the two-layer optical film 120 on the third layer 3 such that the second layer 2 is in contact with the third layer 3 (S160), and the third layer 3 and the two-layer optical Projecting light onto the film 120 to integrate the third layer 3 and the two-layer optical film 120 and to separate the third mold to form the three-layer optical film 130 (S165). Can be.

The light projected in step S165 may be light for complete curing.

In this case, the light projected in step S140 may be light for temporary curing. As described above, the integrated optical film may be manufactured in the form of the two-layer optical film 120 by projecting light for complete curing in step S140. On the other hand, in the case of manufacturing a multilayer optical film having three or more layers by stacking other layers on the second layer 2, the light for temporary curing may be projected in step S140 as in step S115. .

That is, the first integrated optical film manufacturing method (S100) is the n-layer optical film by repeating steps S145, S150, S155, S160, and S165 even after the three-layer optical film 130 is formed as described above Can be formed.

As such, when the steps S145 to S165 are repeated to form the n-layer optical film, the light projected on the n-th layer and the (n-1) -layer optical film of the light projected for each repeated S165 step is light for complete curing. And the remaining light may be light for temporary curing. That is, the integral optical film can be produced by projecting light for temporary curing until lamination of the final layer, and projecting light for complete curing after lamination of the final layer is made.

Alternatively, the production of an integrated optical film can be made in a manner that projects light for complete curing as each layer is laminated. For example, when finally manufacturing an optical film having three layers (excluding the base layer) (see FIG. 15), the temporary curing state on the first layer 1 of the temporary hardening state laminated on the base layer 9 The second layer (2) of the second layer (2) and then fully cured to integrate the two layers, and then the third layer (3) of the temporary hardening state is laminated again and then completely cured to integrate the three layers The manufacture of the film can be made.

Alternatively, the first integrated optical film manufacturing method (S100) is a method of forming the second layer (2) applied to the second integrated optical film manufacturing method (S200), which will be described later, in the formation of three or more multilayer optical films as required. Sticky or tacky material coating after complete curing) can be combined together. For example, the second layer 2 and the third layer 3 may be manufactured according to the first integrated optical film manufacturing method S100, and the fourth layer may be the second in the second integrated optical film manufacturing method S200. It is made according to the manner in which the layer 2 is made, and the fourth layer may be made like the second layer 2 and the third layer 3.

In addition, the first integrated optical film manufacturing method (S100) is a step of passing the third mold, the third layer 3, and the two-layer optical film 120 between the rolls 900 installed at intervals from each other before step S165. It may further include. In this case, the interval between the rolls 700 may be smaller than or equal to the total thickness of the third mold, the third layer 3, and the two-layer optical film 120.

As such, by forming the shape of the layer through preliminary hardening and then sticking or gluing through complete curing, each layer may serve as a pressure-sensitive adhesive or adhesive even without a separate pressure-sensitive adhesive or pressure-sensitive adhesive. The optical film may be provided with a slimmer thickness but is not easily separated from each other, and thus light leakage may be prevented more effectively.

In addition, as described above, in the formation of the layer of the second layer 2 or more, the optical layers stacked on the first layer 1 may be removed by using the release film 99 instead of the base layer 9 and then removing them. It may be formed to have a flat bottom surface without the base layer. In addition, when the bottom surface of each of the optical layers becomes flatter, the incident angle of light incident through the bottom surface may be uniform as a whole, and optical properties such as light uniformity and luminance may be greatly improved.

In the related art, a method of pattern-processing an upper surface after applying resin on a substrate layer is used, which makes it difficult to form a pattern clearly and may cause problems such as resin flowing down around the substrate layer during a pattern processing process. More specifically, when each optical layer is formed in such a manner that the resin is directly applied onto the substrate layer and cured, it becomes very difficult to form a pattern having a desired shape in the optical layer.

For example, if a resin is applied onto a substrate layer and then the shape of the pattern is processed through a press before the resin is cured, the shape of the pressed pattern is difficult to maintain continuously and the resin may flow sideways by press compression. . On the other hand, when the press working after the resin is cured, there is a possibility that the optical layer to form a pattern is damaged or deformed, the press working becomes more difficult. As described above, the method of directly applying the resin on the substrate layer made it impossible to manufacture the optical layer having the pattern in a clear shape.

On the contrary, the present application is to coat the resin on the mold so that the pattern is formed on the lower side, not the upper side of the resin, and the upper side of the resin is formed by first forming a flat bottom surface by covering the easily removable release film 99 and then the release film ( By separating 99), not only the bottom surface is flat but also the pattern can be clearly formed in the desired shape. In addition, the present application used a mold having a surface having a high releasability (peelability) or to make the optical layer in a detachable hardened state on the mold so that each optical layer does not get tangled with the mold during temporary curing or complete curing. .

In addition, according to the application of the mold and the release film 99, all of the base layer except for the base layer 9 supporting the first layer 1 may be omitted, so that the integrated optical to a much slimmer thickness than the conventional optical film Films can be made.

That is, the integrated optical film manufacturing methods disclosed herein combine inventions such that the material side of the optical layer (curable resin), the side of the manufacturing means of the optical layer (using a mold), and the manufacturing process side of the optical layer are organically linked. to be.

Next, an integrated optical film manufacturing method (hereinafter, referred to as a 'second integrated optical film manufacturing method') according to a second embodiment of the present application will be described. However, the same reference numerals are used for the same or similar components as the above-described salping configuration, and redundant descriptions will be briefly or omitted.

6 is a flowchart illustrating a process of manufacturing a two-layer optical film through an integrated optical film manufacturing method according to a second embodiment of the present application, and FIGS. 7A to 7D, 8A to 8E, 9A, and 9B are second It is sectional drawing for demonstrating the integrated optical film manufacturing method which concerns on an Example.

6 and 7A, the second integrated optical film manufacturing method S200 includes coating the curable resin on the first mold 600 having the pattern 610 (S205).

6 and 7B, the second integrated optical film manufacturing method S200 includes covering the base layer 9 on the top surface of the resin coated on the first mold 600 (S210).

6 and 7c, the second integrated optical film manufacturing method (S200) projects the first layer 1 in a fully cured state by projecting light for complete curing onto a resin covered with the base layer 9. And integrally forming the layer 9 (S215). In the step S115 of the first integrated optical film manufacturing method S100, the first layer 1 of the temporary hardened state is formed by projecting light for temporary curing, but in the step S215 of the second integrated optical film manufacturing method S200. The light for complete curing is projected so that the first layer 1 in a fully cured state is formed.

6 and 8A, the second integrated optical film manufacturing method S200 includes coating the curable resin on the second mold 700 having the pattern 710 (S220). 6 and 8B, the second integrated optical film manufacturing method S200 includes covering the release film 99 on the top surface of the resin coated on the second mold 700 (S225). 6 and 8C, in the method of manufacturing a second integrated optical film S200, the cured resin covered with the release film 99 is completely cured to form the second layer 2 in a fully cured state (S230). It includes.

Since the steps S220 to S230 are similar to the steps S120 to S130 of the first integrated optical film manufacturing method S100, detailed descriptions thereof will be omitted.

6, 8D, 8E, and 9A, the second integrated optical film manufacturing method S200 may include a tacky or adhesive material on the second layer 2 from which the release film 99 is removed. 8) coating and stacking the first layer 1 and the base layer 9 separated from the first mold 600 such that the first layer 1 contacts the second layer 2 (S235). It includes. By way of example, the coating of the adhesive or adhesive material 8 may be made by coating the adhesive resin or adhesive resin on the order of 1 to 5 μm.

6 and 9B, the second integrated optical film manufacturing method S200 includes separating the second mold 700 to form the two-layer optical film 120 (S240).

In addition, the second integrated optical film manufacturing method (S200) is the second mold 700, the second layer (2), the first layer (1), and the substrate between the roll 900 installed at intervals after each other after the step S235 It may further comprise passing the layer 9. In this case, the interval between the rolls 900 may be smaller than or equal to the overall thickness of the second mold 700, the second layer 2, the first layer 1, and the base layer 9.

In the second integrated optical film manufacturing method S200, even after the two-layer optical film 120 is formed as described above, by repeating steps S220 to S240 in a similar manner, three or more multilayer optical films may be formed.

Alternatively, the second unitary optical film manufacturing method S200 may include the second layer 2 or the third layer 3 applied to the first unitary optical film manufacturing method S100 in forming a multilayer optical film having three or more layers as necessary. ) Can be combined together (formation after curing). For example, the second layer 2 may be manufactured according to the second integrated optical film manufacturing method S200, and the third layer 3 may be manufactured according to the second integrated optical film manufacturing method S100. Alternatively, the third layer 3 may be manufactured according to the method of manufacturing the third layer 3, and the fourth layer may be manufactured like the second layer 2.

Next, an integrated optical film manufacturing method (hereinafter, referred to as 'a third integrated optical film manufacturing method') according to a third embodiment of the present application will be described. However, the same reference numerals are used for the same or similar components as the above-described salping configuration, and redundant descriptions will be briefly or omitted.

10 is a flowchart illustrating a process of manufacturing a two-layer optical film through the integrated optical film manufacturing method according to the third embodiment of the present application.

Referring to FIG. 10, the third integrated optical film manufacturing method S300 may include coating a curable resin on the first mold 600 having a pattern 610 (S305) and on the first mold 600. Covering the base layer (9) on the top surface of the coated resin (S310), and the step of projecting light for temporary curing on the resin covered with the base layer 9 to form a first layer (1) of the temporary curing state (S315).

In addition, referring to FIG. 10, the third integrated optical film manufacturing method S300 may include coating the curable resin on the second mold 700 having the pattern 710 (S320) and on the second mold 700. Covering the release film 99 on the upper surface of the resin coated on (S325), and the step of completely curing the resin covered with the release film 99 to form a second layer (2) of the fully cured state (S330) Include.

In addition, referring to FIG. 10, the third integrated optical film manufacturing method S300 may coat an adhesive or adhesive material 8 on the second layer 2 from which the release film 99 is removed, and the first mold ( Stacking the first layer 1 and the base layer 9 separated from the layer 600 so that the first layer 1 is in contact with the second layer 2 (S335), and the second layer 2, the second layer Projecting light for complete curing onto the first layer (1) and the base layer (9) to integrate the second layer (2), the first layer (1), and the base layer (9) and to the second mold 700 Separation to form a two-layer optical film 120 (S340).

That is, the third integrated optical film manufacturing method S300 covers the release film 99 on the resin coated on the second mold 700 and then completely cures to form the second layer 2 in the fully cured state. In this regard, there is a difference from the first integrated optical film manufacturing method S100 in which the second layer 2 is first formed in the temporary curing state. Even if the second layer 2 is formed in a fully cured state, it may be integrated when it is completely cured after bonding with the first layer 1 that is temporarily cured, so that the first layer 1 and the second layer 2 may be ), Only the first layer 1 can be formed in a temporary curing state.

In addition, the third integrated optical film manufacturing method S300 may include the second mold 700, the second layer 2, the first layer 1, and the substrate between the rolls 900 installed at intervals from each other before the step S340. It may further comprise passing the layer 9. In this case, the interval between the rolls 900 may be smaller than or equal to the overall thickness of the second mold 700, the second layer 2, the first layer 1, and the base layer 9.

In addition, the 3rd integrated optical film manufacturing method (S300) is the 2nd layer 2 or 3rd layer (3) applied to the 1st integrated optical film manufacturing method (S100) in the formation of a multilayer optical film of three or more layers as needed. ) Or a method of forming the second layer 2 applied to the second integrated optical film manufacturing method (S200) (a material coating method having adhesiveness or adhesiveness after complete curing). The above can be combined together.

Next, an integrated optical film manufacturing method (hereinafter referred to as a 'fourth integrated optical film manufacturing method') (S400) according to the fourth embodiment of the present application will be described. However, the same reference numerals are used for the same or similar components as the above-described salping configuration, and redundant descriptions will be briefly or omitted.

11 is a flowchart illustrating a process of manufacturing a two-layer optical film through the integrated optical film manufacturing method according to the fourth embodiment of the present application.

Referring to FIG. 11, the fourth integrated optical film manufacturing method S400 may include coating a curable resin on a first mold 600 having a pattern 610 (S405) on the first mold 600. Covering the base layer 9 on the top surface of the coated resin (S410), and the light for the complete curing to the resin covered with the base layer 9 to project the first layer (1) of the fully cured state to the base layer ( 9) and forming a single unit (S415).

In addition, referring to FIG. 11, the fourth integrated optical film manufacturing method S400 may include coating the curable resin on the second mold 700 having the pattern 710 (S420) and on the second mold 700. Covering the release film 99 on the upper surface of the resin coated on the (S425), and projecting the light for the temporary curing on the resin covered with the release film 99 to form a second layer (2) of the temporary curing state Step S430 is included.

11, the fourth integrated optical film manufacturing method S400 includes the first layer 1 and the substrate separated from the first mold 600 on the second layer 2 from which the release film 99 is removed. Stacking the layer 9 so that the first layer 1 is in contact with the second layer 2 (S435) and the second layer 2, the first layer 1, and the base layer 9. Projecting light to integrate the second layer 2, the first layer 1, and the base layer 9, and separating the second mold 700 to form the two-layer optical film 120 (S440). It includes.

That is, the fourth integrated optical film manufacturing method (S400) covers the base layer 9 in a resin coated on the first mold 600 and then completely cures the first fully integrated state of the fully cured state with the base layer 9. The first layer 1 is different from the first integrated optical film manufacturing method S100 in which the first layer 1 is first formed in a temporary curing state. Even if the first layer 1 is formed in a fully cured state, the first layer 1 and the second layer 2 may be integrally formed by bonding and fully curing the second layer 2 in a temporary curing state. ), Only the second layer 2 can be formed in a temporary curing state.

Here, the light projected in step S440 may be light for complete curing. In operation S415, the first layer 1 is already completely integrated with the base layer 9 through light projection for complete curing. When the light for the complete curing is projected in step S440, since the second layer 2 is completely cured in a state where the first layer 1 is in contact with each other, the second layer 2 is also the first layer 1. ) And the base layer 9 so that the two-layer optical film 120 may be made of an integrated optical film having integrity.

Alternatively, the light projected in step S440 may be light for temporary curing. As described above, the integrated optical film may be manufactured in the form of the two-layer optical film 120 by projecting light for complete curing in step S440. On the other hand, in the case of manufacturing a multilayer optical film of three or more layers by stacking other layers on the second layer 2, it is preferable to project light for temporary curing in step S440.

That is, the integral optical film can be produced by projecting light for temporary curing until lamination of the final layer, and projecting light for complete curing after lamination of the final layer is made.

In addition, the 4th integrated optical film manufacturing method (S400) is the 2nd layer 2 or 3rd layer 3 applied to the 1st integrated optical film manufacturing method (S100) in the formation of a multilayer optical film of three or more layers as needed. ) Or a method of forming the second layer 2 applied to the second integrated optical film manufacturing method (S200) (a material coating method having adhesiveness or adhesiveness after complete curing). The above can be combined together.

In addition, the fourth integrated optical film manufacturing method S300 may include the second mold 700, the second layer 2, the first layer 1, and the substrate between the rolls 900 installed at intervals from each other before the step S440. It may further comprise passing the layer 9. In this case, the interval between the rolls 900 may be smaller than or equal to the overall thickness of the second mold 700, the second layer 2, the first layer 1, and the base layer 9.

Hereinafter, an integrated optical film according to various embodiments of the present disclosure will be described. However, since the present invention relates to an integrated optical film manufactured through the integrated optical film manufacturing method according to various embodiments of the present disclosure described above, the same reference numerals are used for the same or similar structure as the salping configuration, and the overlapping description will be briefly described. Or omit it.

In addition, the integrated optical film according to various embodiments of the present application may be applied to various fields such as a liquid crystal display (LCD) as well as all light receiving display devices such as electrophoretic displays, signs, lighting, and the like.

First, referring to the drawings (FIGS. 12, 13, 14A, and 14B) of the integrated optical film according to the first embodiment of the present application, the integrated optical film according to various embodiments of the present application (hereinafter 'the integrated optical film') The configuration and technical matters commonly applied to the film) will be described.

12 is a perspective view of the integrated optical film according to the first embodiment of the present application, and FIG. 13 is an exploded perspective view of the integrated optical film according to the first embodiment of the present application. 14A is a plan view from above of a first layer of an integrated optical film according to a first embodiment of the present application, and FIG. 14B is a view from above of another example of a first layer of an integrated optical film according to a first embodiment of the present application. Top view.

This integrated optical film includes the base layer 9. 12, 13, and 15 to 18, the base layer 9 is the most basic layer of each of the layers forming the integrated optical film. The base layer 9 may be a layer that transmits light from the bottom side to the first layer 1. Accordingly, the base layer 35 may have a material having light transmittance.

For example, the base layer 9 may be a flat film shape made of a material such as polyethylene terephthalate (PET), polycarbonate (PC), polyethylene (PE), but is not limited thereto. That is, the base layer 9 may be formed of a material having a predetermined refractive index and light transmittance in order to secure desired luminance and light uniformity.

In addition, a light guide plate (LGP) may serve as the base layer 9. In other words, the substrate layer 9 may be a light guide plate. The light guide plate is a component that converts light incident from a lamp (not shown) into uniform planar light, and is generally made of PMMA (polymethymethacrylate), which is an acrylic resin. Thus, the backlight unit to which the integrated optical film is applied, in which the base layer 9 itself becomes a light guide plate, may be provided more slim.

However, the base layer 9 is not necessarily limited to the light guide plate, and it is preferable that the base layer 9 is understood as a concept that includes all the layers capable of transmitting light from the lower side to the first layer 1 as the bases of the respective layers. Do.

In addition, the integrated optical film includes a first layer (1).

12, 13, and 15 to 18, the first layer 1 is disposed on the base layer 9, and the pattern 11 is formed on the upper surface thereof.

For example, the pattern 11 may be formed according to a regular shape and arrangement as shown in FIG. 14A, or may be formed according to a random size, depth, shape, arrangement, etc., as shown in FIG. 14B. The shape and arrangement of the pattern 11 may be variously set in consideration of the desired degree of light diffusion, the necessity of securing luminance, and the like.

This first layer 1 may be formed of curable resin. By way of example, such a resin may be a curable transparent resin cured by either ultraviolet (UV) or infrared (IR). In addition, the resin may be a resin that is tacky or adhesive. For example, the resin forming the first layer 1 may be a resin that remains tacky even in a hardened state.

And this integrated optical film includes the second layer (2).

The second layer 2 is disposed on the first layer 1, and a pattern 21 is formed on the upper surface.

In addition, the second layer 2 is directly connected with the first layer 1 without the addition of a separate base layer between the first layer 1.

As described above, in the manufacturing method of the integrated optical film according to various embodiments of the present application, in the manufacturing process of the integrated optical film, the substrate supporting the first layer 1 as the mold and the release film are organically linked. In addition to the layer 9, all other base layers, such as the base layer supporting the second layer 2, can be omitted, so that an integrated optical film can be produced with a much slimmer thickness than a conventional optical film.

And the base material layer 9, the 1st layer 1, and the 2nd layer 2 are integrally formed.

As previously described in the integrated optical film manufacturing method according to various embodiments of the present application, in the production of the integrated optical film, at least one method of the complete curing method after the temporary curing and the material coating method having a tacky or adhesive after complete curing By using, the base layer 9, the first layer 1, and the second layer 2 can be integrally formed.

In addition, the lower surface of the second layer 2 may be connected to the first layer 1 in a flat state.

As previously described in the integrated optical film manufacturing method according to various embodiments of the present application, in the production of the integrated optical film, the release film 99 is used instead of the base layer 9 in the formation of the second layer (2) or more. By removing after use, the second layer 2 laminated on the first layer 1 can be formed to have a flat bottom surface. In addition, when the bottom surface of the second layer 2 becomes flatter, the incident angle of light incident through the bottom surface may be uniform as a whole, and optical properties such as light uniformity and luminance may be greatly improved.

This second layer 2 may be formed of curable resin. Since the structure of the 1st layer 1 has been demonstrated about this, detailed description is abbreviate | omitted.

In addition, the integrated optical film may further include one optical layer 3 (see FIG. 15) or a plurality of optical layers (not shown).

Even if the integrated optical film is laminated in three or more layers in this manner, in the manufacturing process of the integrated optical film as described above, all other substrate layers other than the substrate layer 9 supporting the first layer 1 may be omitted. Each layer may have a flat bottom surface, and the pattern formed in each layer is clearly formed in a desired shape.

Therefore, even if the integrated optical film is provided in three or more layers of multilayers, an integrated optical film having a much slimmer, more robust and improved optical characteristic than a conventional multilayer optical film can be realized.

Referring to FIG. 15, when there is one optical layer 3, one optical layer 3 is disposed on the second layer 2 and a pattern 31 is formed on the upper surface thereof. When there is only one optical layer 3, it will be referred to as a third layer (3). One optical layer 3, that is, the third layer 3, is directly connected to the lower second layer 2 without the addition of a separate base layer between the lower second layer 2. In addition, the base material layer 9, the 1st layer 1, the 2nd layer 2, and the 3rd layer 3 are formed integrally.

Alternatively, although not shown in the drawing, when there are a plurality of optical layers, the plurality of optical layers are sequentially disposed on the second layer 2 and a pattern is formed on each top surface. In the case where there are a plurality of optical layers in this way, each of the plurality of optical layers is the lower second layer 2 or the lower optical layer without the addition of a separate base layer between the lower second layer 2 or the lower optical layer. It is directly connected with the layer. In addition, the base material layer 9, the 1st layer 1, the 2nd layer 2, and some optical layer are integrally formed.

On the other hand, based on the above description about this integrated optical film, the integrated optical film which concerns on the 1st-5th Example of this application is examined. However, the integrated optical film implemented through the present disclosure is not limited only to the first to fifth embodiments, but may be implemented in various embodiments corresponding to the description of the integrated optical film described above.

12 and 13, the integrated optical film 120 according to the first embodiment of the present disclosure includes a base layer 9, a first layer 1, and a second layer 2.

Here, the first layer 1 may be a diffusion layer, and the second layer 2 may be a refractive layer.

The diffusion layer may perform a function of diffusing light transmitted from the lower side and transmitting the light to the upper side, and the refraction layer may perform a function of refracting (condensing) the light transmitted from the lower side and transmitting the light to the upper side. However, the diffusion layer may adjust the degree of light diffusion as needed, and in a device in which light diffusion is to be made slightly smaller, light transmission may be performed at a level between diffusion and condensation. In addition, the refractive layer can likewise adjust the degree of condensing as necessary.

In addition, the pattern 11 of the first layer 1 may have a concave shape.

12 and 13, the concave-shaped pattern 11 of the first layer 1 may be formed in a groove recessed downward from the upper surface of the layer 3 of the first layer 1. Can be. The light transmitted through the base layer 9 may be transmitted to the upper second layer 2 in a more uniformly diffused state through the concave pattern 11 formed in the first layer.

The shape of the pattern 11 applied to the diffusion layer is not limited to the concave shape as described above, and may be set in various forms in consideration of efficient light diffusion and luminance improvement.

In addition, the arrangement method of the pattern 11 may also be set in consideration of the desired degree of light diffusion, the necessity of ensuring luminance, and the like. For example, the pattern 11 may be arranged regularly. For example, as illustrated in FIG. 14A, the pattern 11 may be arranged in a honeycomb structure in which one pattern 11 surrounds six other patterns 11. Alternatively, referring to FIG. 14B, the pattern 11 may be formed randomly.

The pattern 21 of the second layer 2 may have a prism pillar shape extending in the length direction of the second layer 2.

The prism column shape may be formed such that the vertex has a triangular shape (prism shape) facing upward. By way of example, the peak angle of a conventional prism is approximately 90 degrees, and it may be desirable to have a value smaller than 90 degrees for more efficient light refraction. However, the shape of the prism pillar need not be limited to a triangular shape, and may be formed in various shapes (angles and pitches) as necessary, such as a refractive direction. In addition, although not shown in the drawings, the surface of the prism may be formed with fine concavities and convexities that can further finely adjust the direction of refraction, brightness, light transmittance, and the like.

15 is a perspective view of an integrated optical film according to a second embodiment of the present application.

Referring to FIG. 15, the unitary optical film 130 according to the second embodiment of the present disclosure may have a base layer 9, a first layer 1, a second layer 2, and a third layer 3 (ie, , One optical layer). Here, the first layer 1 may be a diffusion layer, and the second layer 2 and the third layer 3 may be refractive layers. In addition, the pattern 11 of the first layer 1 has a concave shape, the pattern 21 of the second layer 2 has a prism column shape extending in the longitudinal direction of the second layer, and the third layer 3 ) May have a prism pillar shape extending in the width direction of one optical layer 3 to be orthogonal to the prism pillar-shaped pattern of the second layer 2.

16 is a perspective view of an integrated optical film according to a third embodiment of the present application.

Referring to FIG. 16, the unitary optical film 120 according to the third embodiment of the present disclosure includes a base layer 9, a first layer 1, and a second layer 2. Here, the first layer 1 and the second layer 2 may be refractive layers. In addition, the pattern 11 of the first layer 1 has a prism pillar shape extending in the longitudinal direction of the first layer 1, and the pattern 21 of the second layer 2 is formed of the first layer 1. It may have a prism pillar shape extending in the width direction of the second layer 2 to be orthogonal to the prism pillar-shaped pattern.

17 is a perspective view of an integrated optical film according to a fourth embodiment of the present application.

Referring to FIG. 17, the unitary optical film 120 according to the fourth embodiment of the present disclosure includes a base layer 9, a first layer 1, and a second layer 2. Here, the first layer 1 may be a refractive layer, and the second layer 2 may be a diffusion layer. In this case, the second layer 2, which is a diffusion layer, may be provided as a micro lens film. In addition, the pattern 11 of the first layer 1 may have a prism pillar shape extending in the longitudinal direction of the first layer 1, and the pattern of the second layer 2 may have a convex shape.

18 is a perspective view of an integrated optical film according to a fifth embodiment of the present application.

Referring to FIG. 18, the unitary optical film 120 according to the fifth embodiment of the present disclosure includes a base layer 9, a first layer 1, and a second layer 2. Here, the first layer 1 and the second layer 2 may be diffusion layers. In this case, the first layer 1 and the second layer 2, which are diffusion layers, may be provided as micro lens films. In addition, the pattern 11 of the first layer 1 and the pattern 21 of the second layer 2 may be convex.

It will be understood by those of ordinary skill in the art that the foregoing description of the embodiments is for illustrative purposes and that those skilled in the art can easily modify the invention without departing from the spirit or essential characteristics thereof. It is therefore to be understood that the above-described embodiments are illustrative in all aspects and not restrictive. For example, each component described as a single entity may be distributed and implemented, and components described as being distributed may also be implemented in a combined form.

The scope of the present invention is defined by the appended claims rather than the detailed description, and all changes or modifications derived from the meaning and scope of the claims and their equivalents should be construed as being included within the scope of the present invention.

120: two-layer optical film 130: three-layer optical film
1: first layer 11: pattern
2: second layer 21: pattern
3: third layer (optical layer) 31: pattern
8: sticky or adhesive material 9: substrate layer
99: release film
600: first mold 610: pattern
700: second mold 710: pattern
900: roll

Claims (25)

In the integrated optical film manufacturing method,
(a) coating the curable resin on the first mold having the pattern;
(b) covering the substrate layer on an upper surface of the resin coated on the first mold;
(c) projecting light for temporary curing onto the resin covered with the base layer to form a first layer in a temporary curing state;
(d) coating the curable resin on the second mold having the pattern;
(e) covering the release film on the top surface of the resin coated on the second mold to flatten the top surface of the resin coated on the second mold;
(f) projecting light for temporary curing onto the release film-covered resin to form a second layer in a temporary curing state;
(g) stacking the first layer and the base layer separated from the first mold on the second layer from which the release film is removed; And
(h) a two-layer optical film by projecting light onto the second layer, the first layer, and the base layer to integrate the second layer, the first layer, and the base layer and to separate the second mold; Including forming a step,
In the step (g), the lower surface of the first layer, the pattern corresponding to the pattern of the first mold is formed is in contact with the flat upper surface of the second layer. The method of claim 1,
The light projected in the step (h) is a light for complete curing of the integrated optical film manufacturing method. The method of claim 1,
Before step (h),
Further comprising passing the second mold, the second layer, the first layer, and the substrate layer between rolls spaced apart from each other,
The gap between the rolls is less than or equal to the total thickness of the second mold, the second layer, the first layer and the substrate layer. The method of claim 1,
The light projected in the step (h) is light for temporary curing,
After step (h),
(i) coating the curable resin on the third mold having the pattern;
(j) covering the release film on the upper surface of the resin coated on the third mold;
(k) projecting light for temporary curing onto the release film-covered resin to form a third layer in a temporary curing state;
(l) laminating the two-layer optical film on the third layer from which the release film is removed such that the second layer is in contact with the third layer; And
(m) projecting light onto the third layer and the two-layer optical film to integrate the third layer and the two-layer optical film and to separate the third mold to form a three-layer optical film. Integrated optical film manufacturing method. 5. The method of claim 4,
The light projected in the step (m) is a light for complete curing of the integrated optical film manufacturing method. 5. The method of claim 4,
Before step (m),
Further comprising passing the third mold, the third layer, and the two-layer optical film between rolls spaced from each other,
The gap between the rolls is less than or equal to the total thickness of the third mold, the third layer, and the two-layer optical film. 5. The method of claim 4,
Repeating the steps (i) to (m) to form an n-layer optical film,
The light projected to the nth layer and the (n-1) th layer optical film of the light projected at each repeated (m) step to form the n-layer optical film is light for complete curing, and the remaining light is temporarily hardened. It is light for the integrated optical film manufacturing method. In the integrated optical film manufacturing method,
(a) coating the curable resin on the first mold having the pattern;
(b) covering the substrate layer on an upper surface of the resin coated on the first mold;
(c) projecting light for complete curing onto the resin covered with the substrate layer to form a first layer in a fully cured state with the substrate layer;
(d) coating the curable resin on the second mold having the pattern;
(e) covering the release film on the top surface of the resin coated on the second mold to flatten the top surface of the resin coated on the second mold;
(f) fully curing the resin covered with the release film to form a second layer in a fully cured state;
(g) coating an adhesive or adhesive material on the second layer from which the release film is removed, and laminating the first layer and the base layer separated from the first mold; And
(h) separating the second mold to form a two-layer optical film,
In the step (g), the lower surface of the first layer, the pattern corresponding to the pattern of the first mold is formed is in contact with the flat upper surface of the second layer. 9. The method of claim 8,
After step (g),
Further comprising passing the second mold, the second layer, the first layer, and the substrate layer between rolls spaced apart from each other,
The gap between the rolls is less than or equal to the total thickness of the second mold, the second layer, the first layer and the substrate layer. In the integrated optical film manufacturing method,
(a) coating the curable resin on the first mold having the pattern;
(b) covering the substrate layer on an upper surface of the resin coated on the first mold;
(c) projecting light for temporary curing onto the resin covered with the base layer to form a first layer in a temporary curing state;
(d) coating the curable resin on the second mold having the pattern;
(e) covering the release film on the top surface of the resin coated on the second mold to flatten the top surface of the resin coated on the second mold;
(f) fully curing the resin covered with the release film to form a second layer in a fully cured state;
(g) coating an adhesive or adhesive material on the second layer from which the release film is removed, and laminating the first layer and the base layer separated from the first mold; And
(h) projecting light for complete curing onto the second layer, the first layer, and the substrate layer to integrate the second layer, the first layer, and the substrate layer and to separate the second mold; Forming a two-layer optical film,
In the step (g), the lower surface of the first layer, the pattern corresponding to the pattern of the first mold is formed is in contact with the flat upper surface of the second layer. The method of claim 10,
Before step (h),
Further comprising passing the second mold, the second layer, the first layer, and the substrate layer between rolls spaced apart from each other,
The gap between the rolls is less than or equal to the total thickness of the second mold, the second layer, the first layer and the substrate layer. In the integrated optical film manufacturing method,
(a) coating the curable resin on the first mold having the pattern;
(b) covering the substrate layer on an upper surface of the resin coated on the first mold;
(c) projecting light for complete curing onto the resin covered with the substrate layer to form a first layer in a fully cured state with the substrate layer;
(d) coating the curable resin on the second mold having the pattern;
(e) covering the release film on the top surface of the resin coated on the second mold to flatten the top surface of the resin coated on the second mold;
(f) projecting light for temporary curing onto the release film-covered resin to form a second layer in a temporary curing state;
(g) stacking the first layer and the base layer separated from the first mold on the second layer from which the release film is removed; And
(h) a two-layer optical film by projecting light onto the second layer, the first layer, and the base layer to integrate the second layer, the first layer, and the base layer and to separate the second mold; Including forming a step,
In the step (g), the lower surface of the first layer, the pattern corresponding to the pattern of the first mold is formed is in contact with the flat upper surface of the second layer. The method of claim 12,
The light projected in the step (h) is a light for complete curing of the integrated optical film manufacturing method. The method of claim 12,
Before step (h),
Further comprising passing the second mold, the second layer, the first layer, and the substrate layer between rolls spaced apart from each other,
The gap between the rolls is less than or equal to the total thickness of the second mold, the second layer, the first layer and the substrate layer. In the integrated optical film,
A base layer;
A first layer disposed on the substrate layer and having a pattern formed on an upper surface thereof; And
A second layer disposed on the first layer and having a pattern formed on an upper surface thereof and connected to the first layer in a flat state;
The second layer is directly connected to the first layer without the addition of a separate substrate layer between the first layer,
The substrate layer, the first layer, and the second layer is integrally formed optical film. delete 16. The method of claim 15,
Wherein said first and second layers are formed of a curable resin. 16. The method of claim 15,
Further comprising one optical layer disposed on the second layer and the pattern is formed on the upper surface or a plurality of optical layers sequentially disposed on the second layer and the pattern is formed on the upper surface,
The at least one optical layer is directly connected to the lower second layer or the lower optical layer without the addition of a separate base layer between the lower second layer or the lower optical layer,
Wherein said substrate layer, said first layer, said second layer, and said at least one optical layer are integrally formed. 16. The method of claim 15,
The first layer is a diffusion layer,
The second layer is a refractive layer,
The pattern of the first layer is concave,
The pattern of the second layer is an integral optical film of the prism pillar shape extending in the longitudinal direction of the second layer. 19. The method of claim 18,
The first layer is a diffusion layer,
The second layer is a refractive layer,
The optical layer is one, the one optical layer is a refractive layer,
The pattern of the first layer is concave,
The pattern of the second layer is a prism pillar shape extending in the longitudinal direction of the second layer,
The pattern of the one optical layer is an integral optical film of the prism pillar shape extending in the width direction of the one optical layer to be orthogonal to the pattern of the prism column shape of the second layer. 16. The method of claim 15,
The first and second layers are refractive layers,
The pattern of the first layer is a prism pillar shape extending in the longitudinal direction of the first layer,
The pattern of the second layer is a monolithic optical film of the prism pillar shape extending in the width direction of the second layer to be orthogonal to the pattern of the prism pillar shape of the first layer. 16. The method of claim 15,
The first layer is a refractive layer,
The second layer is a diffusion layer,
The pattern of the first layer is a prism pillar shape extending in the longitudinal direction of the first layer,
The integrated optical film of the second layer is a convex shape. The method of claim 22,
The diffusion layer is an integral optical film that is provided with a micro lens film. 16. The method of claim 15,
The first and second layers are diffusion layers,
The pattern of said first and second layers is a convex shape. 25. The method of claim 24,
The diffusion layer is an integral optical film that is provided with a micro lens film.

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