JP2014059456A - Transfer body for optical film, optical film, and image display device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a transfer body for an optical film that is used for manufacture of an optical film, and allows accurate product inspection.SOLUTION: A transfer body for an optical film includes transfer layers 8, 9, 10, 11, 12, and 13 used for lamination on a transfer target base material, and a support base material 21 that supports the transfer layers 8, 9, 10, 11, 12, and 13. The support base material 21 is a PET film, and has the absolute value of a change in orientation angle within 5 degrees per 500 mm in a direction having the largest change in orientation angle.

Description

  The present invention relates to an optical film such as a pattern retardation film applied to a three-dimensional image display by a passive method, and relates to a transfer body for an optical film and the like when produced by a transfer method.

  In recent years, flat panel displays and the like use various optical films. In addition, in this type of optical film, for example, an antireflection film that reduces reflection of extraneous light by controlling a polarization plane, and a pattern retardation film that is applied to three-dimensional image display by a passive method, alignment of liquid crystal material An optical film that imparts a retardation to transmitted light has been proposed.

  Here, the antireflection film is composed of a linearly polarizing plate and a circularly polarizing plate, and converts external light directed to the panel surface of the image display panel into linearly polarized light by the linearly polarizing plate, and then converts it to circularly polarized light by the subsequent circularly polarizing plate. . Here, the extraneous light by the circularly polarized light is reflected by the surface of the image display panel or the like, but the rotation direction of the polarization plane is reversed during the reflection. As a result, the reflected light is converted from the circularly polarizing plate to linearly polarized light in the direction shielded by the linearly polarizing plate, and then shielded by the subsequent linearly polarizing plate. Is significantly suppressed.

  Regarding this optical film, Patent Document 1 proposes a method of configuring this optical film with positive dispersion characteristics by configuring a circularly polarizing plate by combining a half-wave plate and a quarter-phase plate. Has been. In the case of this method, an optical film can be constituted with positive dispersion characteristics in a wide wavelength band used for displaying a color image.

  On the other hand, the pattern retardation film is an optical film that is applied to passive three-dimensional image display. In the passive method, pixels that are continuous in the vertical direction or the horizontal direction of the image display panel are sequentially and alternately assigned to the right eye and the left eye, and are driven by the image data for the right eye and the left eye, respectively. Thereby, in the passive method, the image for the right eye and the image for the left eye are simultaneously displayed. As a result, the screen of the image display panel is alternately divided into a region for displaying a right-eye image and a region for displaying a left-eye image by a band-shaped region.

  The pattern retardation film converts the light emitted by the linearly polarized light from the right-eye and left-eye pixels into circularly polarized light having different rotation directions for the right-eye and the left-eye, and emits the light. As a result, the pattern retardation film can selectively provide a right-eye image and a left-eye image to the viewer's right eye and left eye, respectively, simply by wearing glasses equipped with a corresponding polarizing filter. As described above, a phase difference corresponding to light emitted from the image display panel is given.

  In these optical films such as antireflection films and patterned retardation films, the liquid crystal material is patterned and cured by the alignment regulating force of the alignment film provided on the transparent substrate. A retardation layer that imparts a phase difference is produced.

  By the way, this type of optical film can be produced by a so-called transfer method. Here, in the transfer method, for example, when a desired layer is formed on a base material, the layer is not directly formed on the base material, but can be peeled once on a releasable support. After forming the transfer body by laminating the layers, the layer formed on the support is finally placed on the base material (transfer base material) on which the layer is to be laminated according to the process, demand, etc. In this method, a desired layer is formed on the substrate by bonding and laminating, and then peeling and removing the support.

  This type of optical film is required to be able to accurately inspect the product even in the state of an intermediate product (which is a transfer body for an optical film) in which a transfer layer is produced on a support produced by such a transfer method.

JP-A-10-68816

  This invention is made | formed in view of such a condition, and it aims at providing the optical film transfer body which can carry out product inspection with sufficient precision.

  The present inventor has intensively studied to solve the above-mentioned problems, and for the transparent film according to the support, the idea of limiting the angle change of the orientation angle to a certain value or less has been reached, thereby completing the present invention. It came to.

(1) a transfer layer to be laminated on a substrate to be transferred;
A support substrate for supporting the transfer layer,
The support base material is a PET film, and the absolute value of the change in the orientation angle in the direction in which the change in the orientation angle is the largest is within 5 degrees per 500 mm.

  According to (1), in the inspection process using polarized light, the occurrence of rainbow unevenness can be reduced, so that inspection of optical characteristics that are difficult due to the occurrence of rainbow unevenness can be performed with high accuracy.

(2) In (1),
The support substrate is
Retardation is 3000 nm or less.

  According to (2), since the occurrence of rainbow unevenness can be further reduced, the optical characteristics can be inspected with higher accuracy.

(3) In (1) or (2),
The transfer layer is
A laminate of a quarter-wave plate retardation layer that imparts a quarter-wave retardation to transmitted light, and a half-wave plate retardation layer that imparts a half-wave retardation to transmitted light. is there.

  According to (3), the optical characteristics can be inspected with high accuracy with respect to the optical film transfer body used for production of an optical film for preventing reflection by controlling polarization.

(4) In (1) or (2),
A quarter-wave plate retardation layer that imparts a quarter-wave retardation to transmitted light, or a half-wave plate retardation layer that imparts a half-wave retardation to transmitted light.

  According to (4), the optical characteristics can be inspected with high accuracy with respect to the optical film transfer body in which the transfer layer functions as a quarter-wave plate and a half-wave plate.

(5) In (1) or (2),
The transfer layer is
It is a retardation layer that imparts a retardation to transmitted light,
The retardation layer is provided with first and second regions having different phase differences to be given to transmitted light.

  According to (5), it is possible to accurately inspect the optical characteristics of the transfer member for an optical film in which the transfer layer functions as a pattern retardation film.

  (6) The transfer layer of the optical film transfer body according to any one of (1), (2), (3), (4), and (5) is laminated on a substrate to be transferred by a linearly polarizing plate. Optical film.

  According to (6), an optical film can be specifically produced using an optical film transfer body whose optical characteristics are accurately inspected.

  (7) An image display device in which the optical film according to (6) is disposed on the front side surface of the image display panel.

  According to (7), an optical film can be arrange | positioned with the transfer body for optical films which test | inspected the optical characteristic with sufficient precision, and an image display apparatus can be comprised.

  With respect to a transfer body for an optical film according to a transfer method used for production of an optical film, product inspection can be performed with high accuracy.

It is a figure which shows the image display apparatus which concerns on 1st Embodiment of this invention. It is a figure where it uses for description of the optical film provided in the image display apparatus of FIG. It is a figure which shows the transfer film applied to the optical film of FIG. It is a figure which shows the manufacturing process of the optical film of FIG. It is a figure which shows the manufacturing process of the transfer film of FIG. It is a figure which shows the continuation of FIG. It is a figure where it uses for description of an inspection process. It is a figure which shows the transfer film which concerns on 2nd Embodiment of this invention. It is a figure which shows the transfer film which concerns on 3rd Embodiment of this invention. It is a figure which shows the transfer film which concerns on 4th Embodiment of this invention.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[First Embodiment]
FIG. 1 is a diagram showing an image display apparatus according to the first embodiment of the present invention. In the image display device 1, the optical film 3 is disposed on the panel surface of the image display panel 2. The image display panel 2 is an organic EL panel having a flexible sheet shape, and displays a desired color image.

  The optical film 3 is an optical film that suppresses reflection of extraneous light arriving at the image display panel 2 by controlling the polarization plane. For this reason, the optical film 3 is configured by laminating a linearly polarizing plate 5 and a circularly polarizing plate 6. The optical film 3 is held by being attached to the panel surface of the image display panel 2 by the pressure-sensitive adhesive layer 4 after peeling the separator film (not shown) and exposing the pressure-sensitive adhesive layer 4 by the pressure-sensitive adhesive. Further, the linearly polarizing plate 5 and the circularly polarizing plate 6 are integrated through the adhesive layer 7.

  The circularly polarizing plate 6 includes a portion 8 (referred to as a retardation layer for a quarter-wave plate) that functions as a quarter-phase plate that imparts a phase difference corresponding to a quarter wavelength to transmitted light, and 1 for transmitted light. / A laminated body with a portion 9 (referred to as a retardation layer for a half-wave plate) that functions as a half-phase plate that imparts a phase difference for two wavelengths. Thereby, the circularly polarizing plate 6 ensures positive dispersion characteristics in a wide wavelength band used for displaying a color image, and the optical film 3 sufficiently suppresses reflection of external light in a wide wavelength band.

  Accordingly, in the image display device 1, the quarter-wave plate retardation layer 8, the half-wave plate retardation layer 9, and the linear polarizing plate 5 are sequentially arranged from the display screen side of the image display panel 2. . Further, as shown in FIG. 2, the slow axes of the half-wave plate retardation layer 9 and the quarter-wave plate retardation layer 8 with respect to the transmission axis of the linearly polarizing plate 5 indicated by arrows (respectively arrows) Are arranged so as to form angles of 15 degrees and 73 degrees counterclockwise, respectively. The optimum angle varies depending on the characteristics of the quarter-wave plate retardation layer 8 and the half-wave plate retardation layer 9, and generally 15 degrees and 75 degrees are optimum. Although it is an angle, it is arranged to form an angle in the range of 13 to 17 degrees and in the range of 71 to 76 degrees.

  More specifically, the quarter-wave plate retardation layer 8 is formed with an in-plane retardation (Re) of 125 nm or more and 150 nm or less, and the half-wave plate retardation layer 9 is provided with an in-plane retardation (Re) Re) is created when 235 nm or more and 285 nm or less. Thereby, the optical film 3 emits the transmitted light in the visible light region wavelength region (450 to 750 nm) incident from the linearly polarizing plate 5 side as circularly polarized light having an ellipticity of 0.8 or more.

  The circularly polarizing plate 6 is provided with a quarter-wave plate shaping resin layer 10, a quarter-wave plate alignment film 11, and a quarter-wave plate retardation layer 8 sequentially from the image display panel 2 side. . The quarter-wave plate shaping resin layer 10 is a shaping resin layer used for shaping a fine uneven shape, and in this embodiment, an ultraviolet curable resin is applied to the shaping resin. In addition, about this ultraviolet curable resin, various resin used for a shaping process, such as an acrylic type, can be applied widely. The quarter-wave plate shaping resin layer 10 has a fine concavo-convex shape formed on the surface by the shaping treatment, and the circularly polarizing plate 6 is 1 in accordance with the surface shape of the quarter-wave plate shaping resin layer 12. A quarter-wave plate alignment film 11 is formed. The quarter-wave plate retardation layer 8 is formed of a liquid crystal material that is solidified (cured) while maintaining refractive index anisotropy, and the circularly polarizing plate 6 has an alignment of the liquid crystal material of ¼ wavelength. Patterning is performed by the alignment regulating force of the plate alignment film 11.

  Subsequently, the circularly polarizing plate 6 is provided with a half-wave plate shaping resin layer 12, a half-wave plate alignment film 13, and a half-wave plate retardation layer 9 in this order. The half-wave plate shaping resin layer 12 is a shaping resin layer used for shaping a fine uneven shape, and in this embodiment, an ultraviolet curable resin is applied to the shaping resin. In addition, about this ultraviolet curable resin, various resin used for a shaping process, such as an acrylic type, can be applied widely. The half-wave plate shaping resin layer 12 has a fine irregular shape formed on the surface by the shaping treatment, and the circularly polarizing plate 6 is 1 in accordance with the surface shape of the half-wave plate shaping resin layer 12. A two-wavelength plate alignment film 13 is formed. The retardation layer 9 for a half-wave plate is formed of a liquid crystal material that is solidified (cured) while maintaining the refractive index anisotropy, and the circularly polarizing plate 6 has an orientation of the liquid crystal material of 1/2 wavelength. Patterning is performed by the orientation regulating force of the plate alignment film 13.

  Here, the fine concavo-convex shape related to the alignment film 13 for ½ wavelength plate and the alignment film 11 for ¼ wavelength plate is formed by a line-shaped uneven shape extending in one direction. Are formed so that the directions extending in the direction of 15 ° and 73 ° counterclockwise with respect to the transmission axis of the linear polarizing plate 5, respectively.

  In the linear polarizing plate 5, the lower surface side of the base material 15 made of a transparent film such as TAC (triacetyl cellulose) is saponified, and then the optical functional layer 16 is disposed. In addition, the base material 15 is replaced with poly (meth) acrylate methyl, poly (meth) acrylate butyl, (meth) acrylate methyl- (meth) acrylate copolymer, (meth) acrylate- A resin such as an acrylic resin such as a styrene copolymer, a glass such as soda glass, potash glass, lead glass, or quartz glass can be used.

The optical functional layer 16 is a part that bears an optical function as a linear polarizing plate, and is produced, for example, by adsorbing and orienting iodine compound molecules on a film material of polyvinyl alcohol (PVA).
[Transcript]
In the optical film 3, the circularly polarizing plate 6 and the linearly polarizing plate 5 are integrated through an adhesive layer 7. A transfer method is applied to the integration process, and the circularly polarizing plate 6 is applied to the linearly polarizing plate 5. The layer structure related to is laminated by a transfer method. Therefore, the substrate to be transferred is the linearly polarizing plate 5, and the layer (transfer layer) used for transfer is a quarter-wave plate shaping resin layer 10, a quarter-wave plate alignment film 11, and a quarter wavelength. It is a laminate of a plate retardation layer 8, a half-wave plate shaping resin layer 12, a half-wave plate alignment film 13, and a half-wave plate retardation layer 9.

  FIG. 3 is a diagram showing a configuration of a transfer film as the transfer body. The transfer film 20 is formed on the support substrate 21 in sequence, the quarter-wave plate shaping resin layer 10, the quarter-wave plate alignment film 11, and the quarter-wave plate position according to the circularly polarizing plate 6. A retardation layer 8, a half-wave plate shaping resin layer 12, a half-wave plate alignment film 13, and a half-wave plate retardation layer 9 are provided.

  Here, the support substrate 21 detachably carries a layer (transfer layer) to be transferred, and after the transfer layer is adhered and laminated on the transfer substrate, it is appropriately peeled off and removed appropriately. It is a substrate. In this embodiment, a PET (Polyethylene terephthalate) film, which is a transparent film material, is applied, whereby the transfer film 20 is configured to be able to inspect optical characteristics. The PET film is corona-treated, thereby appropriately setting the adhesion between the PET film and a release layer described later. In this embodiment, the PET film according to the support substrate 21 has a retardation value of 3000 nm or less, and when the change in the orientation angle is measured in the direction in which the change in the orientation angle is the largest, A material is applied whose absolute value of change is within 5 degrees per 500 mm. In the PET film, the direction with the largest change in the orientation angle is the direction orthogonal to the feeding direction during film production.

  Here, when the change in the orientation angle is large, the so-called rainbow unevenness becomes significant in the PET film at the stage of product inspection by polarized light. This makes it difficult for the transfer film 20 to find defects correctly when optical properties are inspected in the product inspection process. However, if the change in the orientation angle is set to a certain level or less, the occurrence of rainbow unevenness is reduced even when the retardation is large. Thereby, it is possible to correctly inspect the defect in the optical inspection.

  Furthermore, in this embodiment, even when the retardation is 3000 nm or less, rainbow unevenness can be reduced, and the inspection accuracy of optical characteristics can be further improved.

  When the peelability from the transfer layer is insufficient, the support substrate 21 is provided with a release layer that promotes peeling on the transfer layer side. Here, the release layer can be applied with a material that has relatively high adhesion to the support substrate 21 (low releasability) and low adhesion to the transfer layer (high releasability). . In this embodiment, since the lowermost layer of the transfer layer is the quarter-wave plate shaping resin layer 10 made of an ultraviolet curable resin, for example, a silicon resin (organosilicon-based) is used for the support substrate 21 described above. Polymer compound), fluorine-based resin, melamine resin, epoxy resin, or a mixture of these resins and other resins (acrylic resin, cellulose-based resin, polyester resin, etc.) as appropriate. In this embodiment, a release layer made of melamine resin is provided on the support substrate 21 made of the above-described PET film, and wettability with respect to the coating solution of the ultraviolet curable resin provided on the release layer is ensured.

  In this way, instead of providing a release layer made of melamine resin on a corona-treated PET film, a PET film that has not been surface-treated at all may be applied to a support substrate to omit the release layer. Alternatively, a release layer may be omitted by applying a TAC film without a so-called permeation layer called a nonsol to the support substrate. In this way, the configuration can be simplified.

  Incidentally, when the peelability by the release layer is insufficient, a release layer may be provided between the support substrate 21 and the release layer, and this release layer may supplement the peelability by the release layer. . For the release layer, a material having relatively low adhesion to the support film (high peelability) and high adhesion to the release layer (low peelability) can be applied. More specifically, in this embodiment, the release layer includes an acrylic resin, a cellulose resin, a polyester resin, a urethane resin, a vinyl chloride-vinyl acetate copolymer, or a mixture of two or more selected from the above. Alternatively, a mixture of one or more selected from the above and other resins is used. The thickness of the release layer is usually about 1 to 10 μm. Moreover, a peeling layer may be provided in the support base material 21, and may be provided in a peeling layer.

  The quarter-wave plate shaping resin layer 10 is obtained by applying an ultraviolet curable resin coating solution on the support substrate 21 or on the release layer formed on the support substrate 21. The quarter-wave plate alignment film 11 is prepared by coating, and the quarter-wave plate alignment film 11 is applied to a quarter-wave plate using a molding die (roll plate) in which a fine uneven shape for molding is formed on the peripheral side surface. The mold resin layer 10 is formed by a shaping process. The quarter-wave plate retardation layer 8 is formed by applying a liquid crystal material on the quarter-wave plate alignment film 11 and curing it.

  The half-wave plate shaping resin layer 12 is coated with an ultraviolet curable resin on the quarter-wave plate retardation layer 8 in the same manner as the quarter-wave plate shaping resin layer 10. The half-wave plate alignment film 13 is formed by using a molding die in the same manner as the quarter-wave plate alignment film 11. 12 is created by a shaping process. The half-wave plate retardation layer 9 is formed by applying a liquid crystal material on the half-wave plate alignment film 13 and curing it. Thus, in the transfer body, the quarter-wave plate shaping resin layer 10, the quarter-wave plate alignment film 11, the quarter-wave plate retardation layer 8, which has a layer structure related to these circularly polarizing plates, The half-wave plate shaping resin layer 12, the half-wave plate alignment film 13, and the half-wave plate retardation layer 9 are transfer layers used for transfer.

  Further, the transfer film 20 is provided with the adhesive layer 7 and the separator film 23 on the transfer layer according to the layer configuration of the circularly polarizing plate 6.

  Here, the adhesive layer 7 is a layer for adhering the transfer layer and the substrate to be transferred. Depending on the material of the transfer layer and the material of the substrate to be transferred, a material having high adhesion is applied to both. In this embodiment, cellulose resin (cellulose cellulose) such as acetylcellulose (cellulose acetate), nitrocellulose (cellulose nitrate or nitrified cotton), cellulose acetate propionate, poly (meth) methyl acrylate, poly (meta) ) Acrylic resin such as butyl acrylate, methyl (meth) acrylate- (meth) butyl acrylate copolymer, methyl (meth) acrylate-styrene copolymer, urethane resin, polyester resin, vinyl chloride-vinyl acetate Materials such as polymers, ionomers, natural or synthetic rubbers are used. The thickness of the adhesive layer is about 1 to 30 μm. The adhesive layer 7 can also be applied with an ultraviolet curable resin or the like, and when the ultraviolet curable resin is applied, the thickness of the optical film 3 can be further reduced.

  The separator film 23 is a release sheet that covers the surface of the pressure-sensitive adhesive layer 7 so that it can be released. The separator film 23 is provided to prevent the adhesive layer 7 from being exposed and causing unnecessary adhesion to unnecessary articles, and is peeled off and removed immediately before transfer.

[Manufacturing process of optical film]
FIG. 4 is a diagram illustrating a manufacturing process of the optical film 3. In the manufacturing process 30, the base material 15 on which the saponification treatment related to the linearly polarizing plate 5 has been executed and the film material related to the optical function layer 16 are provided by supply rolls 31 and 32. The transfer film 20 is provided by a supply reel 33. In this step 30, the transfer film 20 is pulled out from the supply reel 33, and the separator film 23 is peeled off by the peeling roll 34 to expose the adhesive layer 7. The separated separator film 23 is taken up on a take-up reel 36.

  In this step, the film materials related to the base material 15 and the optical function layer 16 are drawn from the supply rolls 31 and 32, respectively, laminated with the transfer film 20 from which the separator film 23 has been peeled off, and pressed by the pressing rollers 38A and 38B. Thereby, this process 30 unifies the base material 15, the optical function layer 16, and the transfer layer.

  Subsequently, in this step 30, the support base material 21 is peeled off by the peeling roller 39. The peeled support substrate 21 is taken up by a take-up roll 40. Subsequently, after the adhesive for the adhesive layer 4 is applied, the separator film 42 supplied from the supply reel 41 is attached by the pressure rollers 43A and 43B and wound around the take-up reel 44.

[Transfer film manufacturing process]
5 and 6 are schematic diagrams illustrating the manufacturing process of the transfer film 20. In this manufacturing process 50, the support base material 21 is pulled out from the supply reel 51, and a coating solution of an ultraviolet curable resin is applied by the die 52. In this manufacturing process 50, the roll plate 53 is a mold for molding in which the fine uneven shape related to the alignment film 11 for a quarter wavelength plate is formed on the peripheral side surface. In the manufacturing process 50, the support base material 21 coated with the ultraviolet curable resin is pressed against the roll plate 53 by the pressure roller 54, and the ultraviolet curable resin is cured by irradiating the ultraviolet ray with the ultraviolet irradiation device 55 made of a high-pressure mercury lamp. Thereby, the manufacturing process 50 transfers the uneven | corrugated shape formed in the surrounding side surface of the roll plate 53 to the support base material 21. FIG. Thereafter, the support substrate 21 is peeled off together with the ultraviolet curable resin cured from the roll plate 53 by the peeling roller 56, and a liquid crystal material is applied by the die 59. After that, the liquid crystal material is cured by irradiating with ultraviolet rays from the ultraviolet irradiating device 57 and then wound around the take-up reel 58. By this series of processes, the quarter-wave plate shaping resin layer 10, the quarter-wave plate alignment film 11, and the quarter-wave plate retardation layer 8 are formed on the support substrate 21. .

  Subsequently, as shown in FIG. 6, in the manufacturing process of the transfer body, in the subsequent manufacturing process 60, the support base material 21 taken up from the take-up reel 58 is pulled out, and a coating solution of ultraviolet curable resin is applied by the die 62. . In this manufacturing process 60, the roll plate 63 is a mold for molding in which the fine uneven shape related to the alignment film 13 for half-wave plate is formed on the peripheral side surface. In the manufacturing process 60, the support base material 21 to which the ultraviolet curable resin is applied is pressed against the roll plate 63 by the pressure roller 64, and the ultraviolet curable resin is cured by the ultraviolet irradiation by the ultraviolet irradiation device 65 made of a high-pressure mercury lamp. Thereby, the manufacturing process 60 transfers the uneven | corrugated shape formed in the surrounding side surface of the roll plate 63 to the support base material 21. FIG. Thereafter, the support substrate 21 is peeled off together with the ultraviolet curable resin cured from the roll plate 53 by the peeling roller 66, and a liquid crystal material is applied by the die 69. Thereafter, the liquid crystal material is cured by ultraviolet irradiation by the ultraviolet irradiation device 67, and then wound around the take-up reel 68. By a series of processes in this step 60, the quarter-wave plate shaping resin layer 10, the quarter-wave plate alignment film 11 and the quarter-wave plate retardation layer 8 formed on the support substrate 21. Further, a half-wave plate shaping resin layer 12, a half-wave plate alignment film 13, and a half-wave plate retardation layer 9 are sequentially formed. The structure which concerns on the circularly-polarizing plate 6 is created on the top. The transfer body is further provided with an adhesive layer 7 and a separator film 23.

[Transfer film inspection process]
FIG. 7 is a diagram for explaining the inspection process of the transfer film 20. Here, the inspection process 70 inspects the optical characteristics of the transfer film 20 manufactured by sampling. Here, the inspection of the optical characteristics is an inspection of defects in the quarter-wave plate retardation layer 8 and the half-wave plate retardation layer 9 which are retardation layers made of a liquid crystal material. Further, this defect is a so-called alignment defect, a so-called liquid crystal loss or the like.

  In this inspection process 50, the transfer film 20 is disposed between the polarizing plates 71 and 72, and illumination is performed by the light source 73 disposed on the polarizing plate 72 side. In this state, in this inspection step 70, each part is photographed by the imaging device 74, and the photographing result is displayed on the monitor device to inspect the presence or absence of defects in the phase difference layers 8 and 9 of the pattern retardation film 1.

  For this reason, linear polarizing plates are applied to the polarizing plates 71 and 72, and are arranged in a crossed Nicols arrangement. The inclination of the transfer film 20 with respect to the polarizing plates 71 and 72 is adjusted so that the light film has a bright light level. The transfer film 20 is lifted by weighting with a transparent glass plate or the like as necessary, and deformation is prevented. Thus, when the transfer film 20 is arrange | positioned, an orientation defect can be confirmed by the fall of a local luminance level. Thereby, in this inspection process 70, the defect of the transfer film 20 is discovered.

  Here, in the inspection of defects using such polarized light, when the change in the orientation angle of the transfer film 20 on the support substrate 21 is large and the retardation is large, the occurrence of rainbow unevenness becomes significant, thereby detecting the defects. become unable. However, in this embodiment, since the change in the orientation angle is within 5 degrees per 500 mm, the occurrence of rainbow unevenness can be sufficiently suppressed even when the retardation is large. Thereby, the defect can be correctly inspected in the detection of the defect.

  In particular, when the retardation is 3000 nm or less, the rainbow unevenness can be further reduced, thereby further improving the inspection accuracy of the optical characteristics.

  According to the above configuration, by applying a PET film having a change in orientation angle within 5 degrees per 500 mm to the support substrate, defects can be detected in the transfer film with high accuracy. The optical film transfer body functioning as a plate can be inspected with high accuracy.

  Furthermore, when the retardation is 3000 nm or less, product inspection can be performed with higher accuracy.

[Second Embodiment]
FIG. 8 is a view showing a transfer film according to the second embodiment in comparison with FIG. In this transfer film 80, the same configuration as that of the transfer film 20 described above with reference to FIG.

  In this transfer film 80, the transfer layer is composed of the half-wave plate shaping resin layer 12, the half-wave plate alignment film 13, and the half-wave plate retardation layer 9. The two phase difference plate 81 is configured to function. In this embodiment, the transfer layer relating to the transfer film 80 is transferred to a transfer target by a linearly polarizing plate and integrated by a transfer method. Further, it is laminated with a quarter retardation plate, and further laminated with a transfer layer functioning as a quarter retardation plate by a transfer method, so that the polarization plane of the polarizing film is similar to the optical film 1 described above with reference to FIG. An optical film for preventing reflection is produced by control.

  In this embodiment, the transfer layer is divided into a half retardation plate by the half-wave plate shaping resin layer 12, the half-wave plate orientation film 13, and the half-wave plate retardation layer 9. Even when configured to function as, the same effects as in the first embodiment can be obtained.

[Third Embodiment]
FIG. 9 is a view showing a transfer film according to the third embodiment in comparison with FIG. In this transfer film 85, the same configuration as that of the transfer film 20 described above with reference to FIG.

  In this transfer film 85, the transfer layer is composed of the quarter-wave plate shaping resin layer 10, the quarter-wave plate alignment film 11, and the quarter-wave plate retardation layer 8. A four phase difference plate 86 is configured. In this embodiment, a laminate produced by direct lamination of a linearly polarizing plate and a 1/2 retardation plate, or a laminate produced by a transfer method of a linearly polarizing plate and a 1/2 retardation plate, The transfer layer of the transfer film 85 is laminated by a transfer method, and thereby an optical film that prevents reflection by controlling the polarization plane is produced in the same manner as the optical film 1 described above with reference to FIG.

  In this embodiment, a quarter-wave plate is formed by a quarter-wave plate shaping resin layer 10, a quarter-wave plate alignment film 11, and a half-wave plate retardation layer 8. Even when configured to function as, the same effects as those of the above-described embodiment can be obtained.

[Fourth Embodiment]
FIG. 10 is a view showing a transfer film according to the fourth embodiment. In this transfer film 90, the same configurations as those in the above-described embodiment are given the corresponding reference numerals, and redundant descriptions are omitted.

  This transfer film 90 is an optical film transfer body that functions as a pattern phase difference film for three-dimensional image display by a passive method. The transfer film 90 is an optical film in which a linearly polarizing plate and a transfer layer are integrated. In the liquid crystal display panel, this linear polarizing plate is disposed on the exit surface side of the liquid crystal cell, and converts the light emitted from the liquid crystal cell whose polarization surface is modulated by image data into light intensity modulated light. It can be used as a linear polarizing plate. In addition, an image display panel using an organic EL or the like is arranged to convert light emitted from the image display panel by light intensity modulated light into linearly polarized light.

  Here, in the transfer film 90, an alignment film 91 and a retardation layer 92 are sequentially formed on the support substrate 21. The transfer film 90 is formed of a liquid crystal material that is solidified (cured) while the retardation layer 92 maintains refractive index anisotropy, and the alignment of the liquid crystal material is patterned by the alignment regulating force of the alignment film 91. Note that the orientation of the liquid crystal molecules is exaggerated by an elongated ellipse in FIG. By this patterning, the transfer film 90 is a region for the right eye (first region) A, which is a region where the phase difference given to the transmitted light is different by a certain width corresponding to the pixel assignment of the image display panel. And left-eye regions (second regions) B are alternately formed in a band shape, and give phase differences corresponding to light emitted from right-eye and left-eye pixels, respectively.

  The alignment film 91 is formed into a concavo-convex shape by a forming process of the forming resin layer 93 after the forming resin layer 93 is formed on the surface of the support substrate 21 by applying the forming resin. Formed. In this embodiment, an ultraviolet curable resin is applied to the shaping resin. As the ultraviolet curable resin, an acrylate-based, methacrylate-based or epoxy-based monomer, a prepolymer, or a mixture thereof with a photopolymerization initiator such as benzophenone or aromatic iodonium added can be applied. .

  For this reason, in the alignment film 91, strip-shaped regions corresponding to the strip-shaped regions A and B for the right eye and the left eye are alternately formed in order, and minute uneven shapes are respectively produced. Here, the minute concavo-convex shape is formed by a line-shaped (line) concavo-convex shape extending in one direction, and the direction extending in this one direction is a direction different by 90 degrees between the right-eye region A and the left-eye region B. And is inclined at 45 degrees with respect to the extending direction of each region (the horizontal direction, the direction connecting the upper right and the lower left in FIG. 1).

  In this embodiment, even when the transfer layer is configured to function as a pattern retardation film, the same effects as those of the above-described embodiment can be obtained.

[Other Embodiments]
The specific configuration suitable for the implementation of the present invention has been described in detail above, but the present invention can be variously modified and further combined with the configuration of the above-described embodiment without departing from the spirit of the present invention. .

  That is, in the first embodiment described above, the case where the retardation layer that sequentially functions as the quarter retardation plate and the retardation layer that functions as the half retardation plate is described, but the present invention is not limited thereto. However, on the contrary, the present invention can be widely applied to the production of a retardation layer that functions as a ½ retardation plate and a retardation layer that functions as a ¼ retardation plate.

  In the above-described embodiment, the case where the alignment film is formed by the shaping process has been described. However, the present invention is not limited to this, and can be widely applied to the case where the alignment film is formed by a so-called photo-alignment technique. .

  In the above-described embodiment, the case where the retardation layer is formed by aligning the liquid crystal material using the alignment film is described. However, the present invention is not limited to this, and the alignment film is omitted by the liquid crystal polymer having photo-alignment properties. The present invention can be widely applied to the production of a retardation layer.

  Further, in the above-described embodiment, the case where the shaping resin layer related to the alignment film is included in the transfer layer has been described, but the present invention is not limited thereto, and the transfer film is formed between the shaping resin layer and the retardation layer. The present invention can also be widely applied to the case where the forming resin layer is not included in the transfer layer by being separated.

  In the above-described embodiment, the case where the ultraviolet curable resin is applied to the shaping resin has been described. However, the present invention is not limited to this, and various types of shaping resins other than the ultraviolet curable resin can be widely applied. In addition, the present invention can be widely applied to the case where the softened base material is directly pressed against the roll plate for shaping.

  Moreover, although the case where the pattern phase difference film was produced by the roll plate was described in the above-described embodiment, the present invention is not limited to this, and can be widely applied to the case where the pattern phase difference film is produced by a flat plate.

DESCRIPTION OF SYMBOLS 1 Image display apparatus 2 Image display panel 3 Optical film 4, 7 Adhesive layer 5 Linearly polarizing plate 6 Circularly polarizing plate 8 1/2 wavelength plate phase difference layer 9 1/4 long plate phase difference layer 10 1/4 wavelength plate Molding resin layer 11 1/4 wavelength plate alignment film 12 1/2 wavelength plate molding resin layer 13 1/2 wavelength plate alignment film 15 Base material 16 Optical functional layers 20, 80, 85, 90 Transfer film 21 Support base material 23 Separator film 30, 50, 60 Manufacturing process 31, 32, 33, 41, 51 Supply reel 34 Peeling rolls 36, 40, 44, 58, 68 Take-up reels 38A, 38B Pressing roller 39 Peeling roller 43A , 43B, 54, 64 Pressure roller 52, 58, 62, 69 Die 53, 63 Roll plate 55, 57, 65, 67 UV irradiation device 56, 66 Peeling roller 70 Inspection process 71, 72 Polarizing plate 73 Light source
74 Imaging device 81 1/2 retardation plate 86 1/4 retardation plate 91 orientation film 92 retardation layer 93 shaping resin layer

Claims (7)

A transfer layer for lamination to a substrate to be transferred;
A support substrate for supporting the transfer layer,
The said support base material is a PET film, The absolute value of the change of the said orientation angle in the direction with the largest change of an orientation angle is less than 5 degree | times per 500 mm The transfer body for optical films. The support substrate is
The transcription | transfer body for optical films of Claim 1 whose retardation is 3000 nm or less. The transfer layer is
A laminate of a quarter-wave plate retardation layer that imparts a quarter-wave retardation to transmitted light, and a half-wave plate retardation layer that imparts a half-wave retardation to transmitted light. The transfer body for optical films according to claim 1 or 2. The transfer layer is
A phase difference layer for a quarter wavelength plate that imparts a phase difference of a quarter wavelength to transmitted light, or a phase difference layer for a half wavelength plate that imparts a phase difference of a half wavelength to transmitted light. The transfer body for optical films according to 1. The transfer layer is
It is a retardation layer that imparts a retardation to transmitted light,
The transfer body for an optical film according to claim 1, wherein the retardation layer is provided with first and second regions having different retardations for transmitted light. Equipped with a substrate to be transferred by a linear polarizing plate,
An optical film in which the transfer layer of the optical film transfer body according to any one of claims 1, 2, 3, 4, and 5 is laminated on a substrate to be transferred by the linearly polarizing plate. the film. The image display apparatus which has arrange | positioned the optical film of Claim 6 on the surface side of an image display panel.

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