Optical: systems and elements – Single channel simultaneously to or from plural channels – By surface composed of lenticular elements
Reexamination Certificate
1999-10-21
2001-10-16
Mack, Ricky (Department: 2873)
Optical: systems and elements
Single channel simultaneously to or from plural channels
By surface composed of lenticular elements
C359S891000, C427S162000, C430S007000
Reexamination Certificate
active
06304384
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an optical substrate, a manufacturing method therefor, and a display device using the same.
2. Description of the Related Art
One known method for manufacturing a color filter used in a liquid crystal display (LCD), for example, involves filling recesses in a light transmitting layer with a color material. This light transmitting layer can be easily produced by producing a master with a desirably patterned surface, depositing resin on the patterned surface of the master, and then curing and removing the resin to obtain the light transmitting layer.
As taught in Japanese Unexamined Patent Application Publication (kokai) 3-198003 (1991-198003), a manufacturing method for a microlens array used in an LCD can be similarly manufactured by depositing resin on a master having concave surfaces corresponding to the lenses. This resin layer is then cured to form a light transmitting layer, and then the resin is removed to obtain the microlens array.
It is important to note, however, that neither of these methods provides for improving contrast between pixels in a displayed image.
OBJECTS OF THE INVENTION
Therefore, it is an object of the present invention to overcome the aforementioned problems.
With consideration for this problem, therefore, an object of the present With consideration for this problem, therefore, an object of the present invention is to provide a method for easily manufacturing an optical substrate for improving contrast.
The invention further relates to an optical substrate obtained by this manufacturing method, and to a display device in which the obtained optical substrate is used.
SUMMARY OF THE INVENTION
To achieve the aforementioned objects, a manufacturing method for an optical substrate according to the present invention comprises a step for manufacturing a light transmitting layer by pressing tightly together, with a light transmitting layer precursor disposed therebetween, a first master having a plurality of first raised parts dividing a plurality of areas, and a second master having a plurality of second raised parts divided by a plurality of channels. The light transmitting layer thus has a plurality of light shield recesses transferred from a surface profile of the first raised parts, and a plurality of color recesses transferred from a surface profile of the second raised parts. A next step separates the first master from the light transmitting layer. A further step forms a light shield layer by forming at least around openings in the light shield recesses, a layer for repelling a light shield material, and filling the light shield material into the light shield recesses. A further step separates the second master from the light transmitting layer; and a further step forms a color pattern layer by filling a color material into the color recesses.
With this method of the present invention light shield recesses are formed in a light transmitting layer precursor by using the first raised parts (i.e. projections) of the first master as a mold. Color recesses are similarly formed opposite the light shield recesses using the second raised parts (i.e. projections) of the second master as a mold. The light shield recesses are then filled with a light shield material, and the color recesses are filled with a color material. The color material thus forms a color pattern layer, and the light shield material forms a light shield layer. This light shield layer becomes a black matrix. The resulting optical substrate can thus be used as a color filter.
Deformation and voids do not occur in the color material and light shield material because these are simply filled into corresponding recesses and are not separated from the master.
In addition, the masters can be reused multiple times insofar as their durability allows once they are manufactured. Steps for manufacturing the masters in this case can be omitted from the manufacturing process used for second and subsequent color filters, thereby reducing the number of manufacturing steps and contributing to cost reduction.
A top layer that repels the light shield material is also formed at least around the opening to each light shield recess in this exemplary method of the present invention. When the light shield material is then filled into the light shield recesses, this top layer makes it difficult for the light shield material to adhere and remain anywhere other than inside the light shield recesses.
The lines of the black matrix used in a high resolution color filter are extremely fine, and the light shield recesses for forming the black matrix are extremely small. The top layer formed around the openings into the light shield recesses in the present invention, however, enables the light shield material to be filled into the light shield recesses without protruding from and remaining around the recesses. As a result, it is possible using this method of the present invention to manufacture a high precision color filter.
The present invention further relates to an optical substrate manufacturing method comprising a step for manufacturing a light transmitting layer by pressing tightly together, with a light transmitting layer precursor disposed therebetween, a first master having a plurality of raised parts dividing a plurality of areas, and a second master having a plurality of curved parts. This light transmitting layer has a plurality of light shield recesses transferred from a surface profile of the raised parts, and a plurality of lenses transferred from a surface profile of the curved parts. Further steps include: a step for separating the first master from the light transmitting layer; and a step for forming a light shield layer by forming, at least around an opening into the light shield recesses, a layer for repelling a light shield material, and filling said light shield material into the light shield recesses.
With this method of the invention first and second masters are combined with a light transmitting layer precursor therebetween to form lenses transferred from the curved parts of the second master. It is therefore possible to easily manufacture an optical substrate as a microlens array having a plurality of lenses. Screen brightness can also be improved because incident light is converged by each lens.
Light shield recesses are also transferred into this optical substrate from the raised parts of the first master, and are then filled with a light shield material. This light shield material forms a light shield layer, which becomes a black matrix. The light shield layer can thus improve contrast between pixels.
It is therefore possible to easily manufacture, by a transfer molding process, a microlens array whereby both a bright display can be achieved and contrast can be improved.
In addition, the masters can be reused multiple times insofar as their durability allows once they are manufactured. Steps for manufacturing the masters in this case can be omitted from the manufacturing process used for second and subsequent microlens arrays, thereby reducing the number of manufacturing steps and contributing to cost reduction.
A top layer that repels the light shield material is also formed at least around the opening to each light shield recess in this exemplary method of the present invention. When the light shield material is then filled into the light shield recesses, this top layer makes it difficult for the light shield material to adhere and remain anywhere other than inside the light shield recesses.
When the resulting microlens array is used with a LCD panel requiring high resolution, the lines of the black matrix are extremely fine. The light shield recesses for forming the black matrix are therefore extremely small. The top layer formed around the openings to the light shield recesses in the present invention, however, enables the light shield material to be filled into the light shield recesses without protruding from and remaining around the recesses. As a result, it is possible using this method of the present
Mack Ricky
Seiko Epson Corporation
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