JP4069337B2 - Manufacturing method of microlens array - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a microlens array in which an alignment film is integrally formed, a manufacturing method thereof, and a display device.
[0002]
BACKGROUND OF THE INVENTION
So far, a microlens array configured by arranging a plurality of minute lenses has been applied to, for example, a liquid crystal panel. By applying the microlens array, light incident on each pixel is collected by each lens, so that the display screen can be brightened.
[0003]
As a method for manufacturing a microlens array, a method using a dry etching method or a wet etching method is known. However, according to these methods, a lithography process is required every time an individual microlens array is manufactured, and the cost increases.
[0004]
Therefore, as disclosed in Japanese Patent Laid-Open No. 3-198003, a method of manufacturing a microlens array by dripping a resin on a master having a curved surface corresponding to a lens, solidifying and peeling the resin. Has been developed.
[0005]
In short, this method is a method that eliminates the lithography process for each product by transferring and forming the microlens array using the master as a mold. Once the master is manufactured, it can be used repeatedly as long as the durability permits. Therefore, the higher the durability of the master, the lower the cost of the master per product, leading to lower product costs.
[0006]
An alignment film is then formed on the microlens array for the liquid crystal panel. The alignment film performs alignment processing of liquid crystal molecules and requires flatness. In addition, the alignment film is formed by, for example, applying a polyimide resin and baking it. However, the heat of the alignment film not only adversely affects the microlens array, but also has a problem that it is restricted by the material constituting it. is there.
[0007]
The present invention solves such problems, and an object of the present invention is to provide a method for manufacturing a microlens array having an alignment film at low cost, a microlens array manufactured by the method, and a display device therefor. There is.
[0008]
[Means for Solving the Problems]
(1) A manufacturing method of a microlens array according to the present invention includes a first step of forming an alignment film on a base,
A second step of providing a light-transmitting layer having a plurality of lenses on the alignment film;
A third step of peeling the alignment film integrally with the light-transmitting layer from the base;
including.
[0009]
According to the present invention, since the alignment film is formed on the base, it is easy to ensure the flatness of the alignment film. Moreover, in this invention, after baking and forming an alignment film, a light transmissive layer is provided on it. Therefore, when the alignment film is baked, the light-transmitting layer is not yet formed. Therefore, the light-transmitting layer is not affected by the high temperature during baking. Moreover, since the material which comprises a light transmissive layer is not limited to what can endure the high temperature at the time of baking, the freedom degree of material selection increases.
[0010]
(2) In the manufacturing method of the microlens array,
Before the second step, including the step of forming the light transmissive layer separately from the alignment film,
In the second step, the completed light transmissive layer may be bonded to the alignment film.
[0011]
According to this, since the light-transmitting layer with a lens obtained in advance can be used, it becomes a versatile manufacturing method.
[0012]
(3) In the manufacturing method of the microlens array,
In the second step, a light transmissive layer may be adhered to the alignment film while being formed on the base from the light transmissive layer precursor.
[0013]
According to this, since the alignment film and the light transmissive layer are continuously formed, the overall process can be shortened.
[0014]
(4) In the manufacturing method of the microlens array,
The base has radiation transparency,
In the third step, the alignment film may be irradiated with the radiation through the base to reduce the bonding force at the interface between the alignment film and the base.
[0015]
Thus, the alignment film can be easily peeled from the base by reducing the bonding force at the interface between the alignment film and the base.
[0016]
(5) In the manufacturing method of the microlens array,
In the first step, a separation layer is previously formed on the base, and the alignment film is formed on the separation layer,
The base has radiation transparency,
In the third step, the separation layer may be irradiated with the radiation through the base to reduce the bonding force at the interface between the base and the separation layer.
[0017]
According to this, the bonding force at the interface between the base and the separation layer is reduced, and the separation layer can be peeled from the base.
[0018]
(6) In the manufacturing method of the microlens array,
In the first step, a separation layer is previously formed on the base, and the alignment film is formed on the separation layer,
The base has radiation transparency,
In the third step, the separation layer may be irradiated with the radiation through the base to reduce the bonding force at the interface between the alignment film and the separation layer.
[0019]
According to this, the bonding force at the interface between the alignment film and the separation layer is reduced, and the alignment film can be peeled from the separation layer.
[0020]
(7) In the manufacturing method of the microlens array,
In the first step, a separation layer is previously formed on the base, and the alignment film is formed on the separation layer,
The base has radiation transparency,
In the third step, the separation layer may be irradiated with the radiation through the base to reduce the bonding force inside the separation layer.
[0021]
According to this, the bonding force inside the separation layer is reduced, and peeling (cohesive failure) occurs inside the separation layer. Therefore, a part of the separation layer adheres to the microlens array, and the rest of the separation layer adheres to the base.
[0022]
(8) In the manufacturing method of the microlens array,
A step of cleaning the surface of the alignment film may be included after the third step.
[0023]
By doing so, it is possible to remove a part of the alignment film that has deteriorated due to the irradiation of radiation.
[0024]
(9) In the manufacturing method of the microlens array,
A step of removing the separation layer attached to the surface of the alignment film may be included after the third step.
[0025]
By doing so, it is possible to remove the separation layer or the debris attached to the microlens array.
[0026]
(10) In the manufacturing method of the microlens array,
At least one recess is formed on the surface of the base,
In the first step, the concave portion of the base is filled with the material of the alignment film to form a convex portion integrated with the alignment film,
The convex portion may serve as a support member (spacer) for maintaining a constant interval (cell gap) for enclosing liquid crystal in the liquid crystal panel (liquid crystal cell).
[0027]
According to this method, the support member can be formed simultaneously with the alignment film, and the arrangement position of the support member can be easily adjusted.
[0028]
(11) The concave portion is formed in a region corresponding to the space between the lenses on the base,
The second step may be performed by positioning the concave portion of the base between the lenses.
[0029]
By this method, it is possible to prevent the support member from being formed on the lens, so that the yield can be improved and the manufacturing process can be simplified.
[0030]
(12) In the method for manufacturing the microlens array,
In a predetermined region on the surface of the base, a protrusion corresponding to the alignment groove formed in the alignment film is formed,
In the first step, the alignment groove may be formed in a predetermined region of the alignment film.
[0031]
According to this, since the alignment groove can be simultaneously formed on the alignment film in the alignment film forming process, the process can be shortened. Here, the alignment groove refers to a groove for aligning liquid crystal molecules in a predetermined direction.
[0032]
(13) In the manufacturing method of the microlens array,
Forming a transparent electrode film on one of the alignment film and the light transmissive layer,
In the second step, the light transmissive layer may be provided on the alignment film via the transparent electrode film.
[0033]
By doing so, a microlens array having a transparent electrode film can be easily manufactured.
[0034]
(14) In the manufacturing method of the microlens array,
The transparent electrode film may be formed on the alignment film.
[0035]
By doing so, since the transparent electrode film can be annealed separately from the light transmissive layer, the light transmissive layer can be prevented from being affected by heat.
[0036]
(15) The microlens array according to the present invention is manufactured by the above method.
[0037]
(16) A display device according to the present invention includes the microlens array and a light source that emits light toward the microlens array.
[0038]
DETAILED DESCRIPTION OF THE INVENTION
Preferred embodiments of the present invention will be described below with reference to the drawings.
[0039]
(First embodiment)
FIG. 1A to FIG. 6C are diagrams for explaining a first embodiment of the present invention.
[0040]
(Master production process)
FIG. 1A to FIG. 1E are diagrams illustrating a process of manufacturing a master in the first embodiment.
[0041]
First, as shown in FIG. 1A, a resist layer 14 is formed on a substrate 12. The substrate 12 is used for etching the surface to form a master 10 (see FIG. 1E), and is not particularly limited as long as it is a material that can be etched. Since it is easy to form the accurate curved surface portion 19 (see FIG. 1E), it is preferable.
[0042]
As a substance for forming the resist layer 14, for example, a commercially available positive type resist in which a diazonaphthoquinone derivative is blended as a photosensitizer with a cresol novolak resin, which is generally used in semiconductor device manufacturing, can be used as it is. Here, the positive type resist is a substance that can be selectively removed by a developing solution by exposing the area exposed to radiation according to a predetermined pattern.
[0043]
As a method for forming the resist layer 14, a spin coating method, a dipping method, a spray coating method, a roll coating method, a bar coating method, or the like can be used.
[0044]
Next, as shown in FIG. 1B, a mask 16 is placed on the resist layer 14, and only a predetermined region of the resist layer 14 is exposed by the radiation 18 through the mask 16.
[0045]
The mask 16 is patterned so that the radiation 18 is transmitted only in a region necessary for forming the curved surface portion 19 shown in FIG.
[0046]
Moreover, it is preferable to use light having a wavelength of 200 nm to 500 nm as the radiation. The use of light in this wavelength region enables the use of photolithography techniques established in the liquid crystal panel manufacturing process and the like and the equipment used therefor, thereby reducing costs.
[0047]
When the resist layer 14 is exposed to the radiation 18 and then developed under predetermined conditions, only the resist layer 14 in the exposed region 17 of the radiation 18 is selectively removed as shown in FIG. The surface of the substrate 12 is exposed, and the remaining region remains covered with the resist layer 14.
[0048]
When the resist layer 14 is thus patterned, as shown in FIG. 1D, the substrate 12 is etched to a predetermined depth using the resist layer 14 as a mask. Specifically, isotropic etching is performed on the region of the substrate 12 exposed from the resist layer 14 in which the etching proceeds in any direction. For example, isotropic etching can be performed by applying wet etching and immersing the substrate 12 in a chemical solution (etching solution). When quartz is used as the substrate 12, etching is performed using, for example, an aqueous solution (buffered hydrofluoric acid) in which a boiling acid and ammonium fluoride are mixed as an etching solution. By performing isotropic etching, a concave curved surface portion 19 is formed on the substrate 12. In addition, the curved surface part 19 is equal to the inverted shape of the lens 42 (see FIG. 4C) of the light transmissive layer 40 to be finally produced, and is a curved surface.
[0049]
Next, when the resist layer 14 is removed after the etching is completed, a curved surface portion 19 is formed on the substrate 12 as shown in FIG.
[0050]
In this embodiment, the master 10 is economical because once it is manufactured, it can be used as many times as the durability allows. Further, the manufacturing process of the master 10 can be omitted in the manufacturing process of the second and subsequent microlens arrays, and the number of processes can be reduced and the cost can be reduced.
[0051]
In the above embodiment, a positive resist is used when the curved surface portion 19 is formed on the substrate 12. However, a region exposed to radiation becomes insoluble in the developer and a region not exposed to radiation is present. A negative resist that can be selectively removed by a developer may be used. In this case, a mask having a pattern reversed from that of the mask 16 is used. Alternatively, the resist may be directly exposed in a pattern by a laser beam or an electron beam without using a mask.
[0052]
(Intermediate board manufacturing process)
FIG. 2A to FIG. 2C are diagrams showing a process of forming an intermediate board. First, as shown in FIG. 2A, the intermediate disk precursor 22 is placed on the surface of the master disk 10 having the curved surface portion 19. Then, the reinforcing plate 20 is brought into close contact with the master 10 via the intermediate master precursor 22, thereby spreading the intermediate master precursor 22 to a predetermined area and reinforcing the master 10 as shown in FIG. A layer made of the intermediate plate precursor 22 is formed between the plates 20.
[0053]
Here, the intermediate disk precursor 22 is placed on the master 10, but it may be placed on the reinforcing plate 20 or on both the master 10 and the reinforcing plate 20. Further, the intermediate plate precursor 22 is previously applied to a predetermined region on either or both of the master 10 and the reinforcing plate 20 by a spin coating method, a spray coating method, a roll coating method, a bar coating method, a dipping method, or the like. It may be spread to.
[0054]
The reinforcing plate 20 is used to reinforce the intermediate plate 24, and is particularly limited as long as it has process resistance in the step of manufacturing the intermediate plate 24 and the step of manufacturing the replica plate 30 from the intermediate plate 24. Instead, for example, a substrate made of quartz, glass, resin, metal or ceramic can be used. The reinforcing plate 20 is not necessary if the intermediate plate 24 alone can satisfy the process resistance.
[0055]
In the process of forming the replica disk 30 from the intermediate disk 24 in the subsequent process, the intermediate disk precursor 22 has good releasability from the master disk 10 and transferability of the shape of the curved surface portion 19. The material is not particularly limited as long as it is a material having resistance and good transferability of the shape of the curved surface portion 26 from the intermediate plate 24 to the replica plate 30. However, the intermediate disc precursor 22 is preferably a liquid or a liquefiable substance. By making it liquid, it becomes easy to fill the plurality of curved surface portions 19 of the master disk 10 with the intermediate disk precursor 22. As the liquid substance, a substance curable by applying energy can be used, and as the liquefiable substance, a plastic substance can be used.
[0056]
Moreover, when selecting resin as the intermediate | middle board | substrate precursor 22, what has energy sclerosis | hardenability or what has plasticity is suitable.
[0057]
It is desirable that the resin having energy curability be curable by applying at least one of light and heat. The use of light and heat can use a general-purpose exposure apparatus, a heating apparatus such as a bake furnace or a hot plate, and can reduce equipment costs.
[0058]
As such resin having energy curability, for example, acrylic resin, epoxy resin, melamine resin, polyimide resin and the like can be used. In particular, an acrylic resin is suitable because it can be easily cured in a short time by irradiation with light by using various precursors and photosensitizers (photopolymerization initiators) on the market.
[0059]
Specific examples of the basic composition of the photocurable acrylic resin include prepolymers or oligomers, monomers, and photopolymerization initiators.
[0060]
Examples of the prepolymer or oligomer include acrylates such as epoxy acrylates, urethane acrylates, polyester acrylates, polyether acrylates, spiroacetal acrylates, epoxy methacrylates, urethane methacrylates, polyester methacrylates, and polyethers. Methacrylates such as methacrylates can be used.
[0061]
Examples of the monomer include 2-ethylhexyl acrylate, 2-ethylhexyl methacrylate, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, N-vinyl-2-pyrrolidone, carbitol acrylate, tetrahydrofurfuryl acrylate, isobornyl acrylate, Monofunctional monomers such as dicyclopentenyl acrylate and 1,3-butanediol acrylate, 1,6-hexanediol diacrylate, 1,6-hexanediol dimethacrylate, neopentyl glycol diacrylate, neopentyl glycol dimethacrylate, ethylene Bifunctional monomers such as glycol diacrylate, polyethylene glycol diacrylate, pentaerythritol diacrylate, and trimethylo Propane triacrylate, trimethylol propane trimethacrylate, pentaerythritol triacrylate, polyfunctional monomers such as dipentaerythritol hexaacrylate available.
[0062]
Examples of the photopolymerization initiator include acetophenones such as 2,2-dimethoxy-2-phenylacetophenone, butylphenones such as α-hydroxyisobutylphenone and p-isopropyl-α-hydroxyisobutylphenone, and p-tert-butyl. Halogenated acetophenones such as dichloroacetophenone, p-tert-butyltrichloroacetophenone, α, α-dichloro-4-phenoxyacetophenone, benzophenones such as benzophenone, N, N-tetraethyl-4,4-diaminobenzophenone, benzyl, benzyl Benzyls such as dimethyl ketal, benzoins such as benzoin and benzoin alkyl ether, oximes such as 1-phenyl-1,2-propanedione-2- (o-ethoxycarbonyl) oxime, 2-methyl Thioxanthone, 2-xanthones such as chlorothioxanthone, Michler's ketone, radical generating compounds such as benzyl methyl ketal are available.
[0063]
If necessary, a compound such as amines may be added for the purpose of preventing curing inhibition by oxygen, or a solvent component may be added for the purpose of facilitating coating. The solvent component is not particularly limited, and various organic solvents such as propylene glycol monomethyl ether acetate, methoxymethyl propionate, ethoxyethyl propionate, ethyl lactate, ethyl pyruvate, methyl amyl ketone, etc. Is available.
[0064]
These substances are preferable because they have excellent releasability from silicon or quartz, which is excellent as a master material in that high-precision etching is possible.
[0065]
Moreover, as resin which has plasticity, resin which has thermoplasticity, such as a polycarbonate-type resin, a polymethylmethacrylate-type resin, an amorphous polyolefin-type resin, can be utilized, for example. Such a resin is plasticized by heating it above the softening point temperature, and is made into a liquid form. As shown in FIG. 2B, the resin is plasticized after being sandwiched between the master 10 and the reinforcing plate 20. Is solidified by cooling, the intermediate plate 24 is formed.
[0066]
By bringing the master 10 and the reinforcing plate 20 into close contact with each other through such an intermediate master precursor 22, the intermediate master precursor 22 has a shape corresponding to the curved surface portion 19 of the master 10. If necessary, when the master 10 and the reinforcing plate 20 are bonded together, pressure may be applied through at least one of the master 10 and the reinforcing plate 20. By pressurizing, the time required for the intermediate plate precursor 22 to spread and spread to a predetermined area can be shortened, so that workability is improved and filling of the curved surface portion 19 is ensured.
[0067]
And the solidification process according to the intermediate | middle board | substrate precursor 22 is given. For example, if a photo-curable resin is used, light is irradiated under predetermined conditions. As a result, the intermediate plate precursor 22 is solidified to form the intermediate plate 24 as shown in FIG.
[0068]
Next, as shown in FIG. 2C, the intermediate plate 24 and the reinforcing plate 20 are peeled from the master 10. In the intermediate plate 24 obtained in this way, a convex curved surface portion 26 is formed corresponding to the concave curved surface portion 19 of the master 10.
[0069]
(Duplicator production process)
FIG. 3A to FIG. 3C are diagrams showing a process of forming a replica disc from an intermediate disc. First, as shown in FIG. 3A, a metal film 32 is formed on the surface of the intermediate board 24 on which the curved surface portion 26 is formed, and the surface is made conductive (body). As the metal film 32, for example, nickel (Ni) is 500 to 1000 angstroms (10 ^-Ten m 2). As a method for forming the metal film 32, it is possible to use a method such as sputtering, CVD, vapor deposition, or electroless plating. In addition, if the surface of the intermediate | middle board 24 has the electroconductivity required in formation of the metal layer by the subsequent electroforming method, this electroconductivity is unnecessary.
[0070]
Then, Ni is further electrodeposited by electroforming using the metal film 32 as a cathode and chip-shaped or ball-shaped Ni as an anode to form a thick metal layer 34 as shown in FIG. An example of the electroplating solution is shown below.
[0071]
Nickel sulfamate: 550 g / l
Boric acid: 35 g / l
Nickel chloride: 5g / l
Leveling agent: 20 mg / l
Subsequently, as shown in FIG. 3C, the duplicate film 30 is obtained by peeling the metal film 32 and the metal layer 34 from the intermediate board 24 and washing them if necessary. A concave curved surface portion 36 is formed on the duplicated disk 30 corresponding to the convex curved surface portion 26 of the intermediate disk 24. The curved surface portion 36 has a reverse pattern for forming the lens 42 shown in FIG. 4C by transfer.
[0072]
Further, the metal film 32 may be removed from the duplication board 30 by performing a peeling process as necessary.
[0073]
(Light transmissive layer forming step)
Next, FIGS. 4A to 4C are diagrams illustrating a process of forming a light-transmitting layer having a plurality of lenses.
[0074]
First, as shown in FIG. 4A to FIG. 4B, the replica disc 30 and the reinforcing plate 44 are brought into close contact with each other through the light transmitting layer precursor 38. This process is the same as the process shown in FIGS. 2A to 2B, and the light-transmitting layer precursor 38 is also made of a material that can be selected as the intermediate plate precursor 22 shown in FIG. 2A. Although it can be selected, it must be light transmissive. In particular, the acrylic resin is cured in a short time by light irradiation by using various commercially available precursors and photosensitizers (photopolymerization initiators), and the light-transmitting layer 40 having excellent optical characteristics. Can be formed, which is preferable.
[0075]
The reinforcing plate 44 is not particularly limited as long as it satisfies optical properties such as light transmittance required for a microlens array and characteristics such as mechanical strength. It is possible to use a glass substrate, or a plastic substrate or film such as polycarbonate, polyarylate, polyethersulfone, polyethylene terephthalate, polymethyl methacrylate, amorphous polyolefin or the like. Note that the reinforcing plate 44 is not necessary if the light-transmitting layer 40 alone can satisfy characteristics such as mechanical strength required for the microlens array.
[0076]
When the light transmissive layer 40 is thus formed on the replica disc 30, the light transmissive layer 40 and the reinforcing plate 44 are integrally peeled from the replica disc 30 as shown in FIG. Since the light transmissive layer 40 includes a plurality of lenses 42 transferred from the curved surface portion 36, a configuration including the light transmissive layer 40 and the reinforcing plate 44 is generally referred to as a microlens array. However, in the present application, a configuration in which at least the alignment film 51 (see FIG. 6C) is added to this is defined as a microlens array.
[0077]
In short, in the above process, the intermediate plate 24 is manufactured from the master 10 having the curved surface portion 19, the duplicate plate 30 is duplicated based on the intermediate plate 24, and the duplicate plate 30 is used for each product to reinforce the reinforcing plate. This is a method of forming a light-transmitting layer 40 (generally a microlens array) reinforced by 44. According to this, since the expensive master 10 is used only when the intermediate master 24 is manufactured, the frequency of the master 10 being deteriorated and remanufacturing is reduced, and the manufacturing cost of the microlens array in a general sense is reduced. Can do. Further, since the replica disk 30 is not directly formed from the master disk 10, the range of selection of both materials is widened, and the degree of freedom of the method for forming the replica disk 30 is increased, so that the shape of the curved surface portions 26 and 36 can be made with high accuracy. It becomes easy to transfer. Furthermore, it becomes easy to improve the durability of the master 10 and the replica 30.
[0078]
(Alignment film formation process)
5A and 5B are diagrams illustrating a process of forming an alignment film. 5A, the alignment film 51 is formed by providing a polyimide resin or a precursor material thereof on a base 50 by a method such as coating, and baking it at 100.degree. C. to 350.degree. As a coating method, a spin coating method, a roll coating method, a flexographic printing method, or the like can be used. The firing temperature is appropriately set according to the material used. The alignment film 51 is formed separately from the steps shown in FIGS. 1A to 4C, but the formation time may be simultaneous or different.
[0079]
Thereafter, as shown in FIG. 5B, a transparent electrode film 52 is formed on the alignment film 51 formed on the base 50. The transparent electrode film 52 is, for example, an ITO (Indium Tin Oxide) film or the like, and is formed by a vacuum film forming method such as sputtering or vapor deposition, and then annealed. The temperature of the annealing treatment is usually 100 to 300 ° C., but generally the higher the temperature, the lower the resistance value and the better the electrode film, which is preferable. Note that baking for forming the alignment film 51 and annealing treatment of the transparent electrode film 52 may be performed simultaneously.
[0080]
In order to form the alignment film 51 and the transparent electrode film 52 flat with a uniform thickness, the surface of the base 50 is preferably flat. Specifically, the unevenness of the base 50 is desirably within ± 0.1 μm. Thereafter, the base 50 supports the alignment film 51 and the transparent electrode film 52 until they are transferred onto the light-transmitting layer 40 (microlens array in a general sense) reinforced by the reinforcing plate 44. It becomes the substrate for. Here, as the base 50, if necessary in a later step, one having radiation transparency is used. The base 50 is required to withstand the firing temperature when forming the alignment film 51 and the annealing temperature when forming the transparent electrode film 52.
[0081]
Next, as illustrated in FIG. 5C, a light blocking layer 54 is formed over the transparent electrode film 52. The light shielding layer 54 is a black matrix for the pixels of the display device, and is formed so as to shield a predetermined area according to the pixel arrangement.
[0082]
(Alignment film adhesion process)
Next, as shown in FIG. 6A, the side of the base 50 on which the light shielding layer 54 and the like are formed and the side of the light transmissive layer 40 on which the lens 42 is formed are bonded to each other. Paste through. Specifically, the adhesive layer precursor 56 is dropped or applied to at least one of the base 50 or the light transmissive layer 40, and the two are bonded together. The adhesive layer precursor 56 is the weight of the reinforcing plate 44 and the light-transmitting layer 40 (the weight of the base 50 when the base 50 is disposed on the upper side during bonding) or the light-transmitting layer 40 or the base. By being pressurized through 50, both are brought into close contact with each other and bonded.
[0083]
Here, the adhesive layer precursor 56 is not particularly limited as long as it has optical transparency and adhesion, and a material that can be cured by applying energy, a material that has plasticity, or the like is also used. be able to. For example, a material that can be selected as the light-transmitting layer precursor 38 shown in FIG. 4A can be selected.
[0084]
Thus, the light-transmitting layer 40 reinforced by the reinforcing plate 44 and the base 50 on which the alignment film 51, the transparent electrode film 52, and the light-shielding layer 54 are formed are as shown in FIG. The adhesive layer 58 is in a state of being bonded.
[0085]
(Base peeling process)
Next, the base 50 is peeled off, but depending on the combination of the substances constituting the base 50 and the alignment film 51, the adhesion between them becomes high, and the alignment film 51 becomes difficult to peel from the base 50. When there is a problem such as an increase in the defective product generation rate such as missing alignment film 51 or occurrence of cracks, a decrease in productivity due to the time required for peeling, and a decrease in durability of the base 50 There is.
[0086]
Therefore, as shown in FIG. 6B, the radiation 60 is irradiated to the interface between the alignment film 51 and the base 50 through the base 50. By doing so, the adhesion between the alignment film 51 and the base 50 can be reduced or eliminated, and the alignment film 51 can be favorably peeled from the base 50 as shown in FIG.
[0087]
Specifically, at the interface between the base 50 and the alignment film 51, various bonding forces between atoms or molecules may be reduced or eliminated, and a phenomenon such as ablation may be caused to cause interface peeling (destruction). it can. Alternatively, the component contained in the alignment film 51 is vaporized and released by the radiation 60, so that a separation effect may be exhibited and contribute to interface peeling.
[0088]
Thus, in order to cause interface peeling by irradiation of the radiation 60, the base 50 needs to be made of a material that transmits the radiation 60, and the alignment film 51 needs to be made of a material that absorbs the energy of the radiation 60. is there.
[0089]
Here, the transmittance of the radiation 60 of the base 50 is preferably 10% or more, particularly preferably 50% or more. It is preferable that the transmittance of the radiation 60 in the base 50 is high so that the attenuation when the irradiated radiation 60 passes through the base 50 can be reduced and a phenomenon such as ablation can be caused with small energy. An example of the base 50 is quartz. Quartz has high light transmittance in the short wavelength region and is excellent in mechanical strength and heat resistance.
[0090]
Examples of the radiation 60 include deep UV light. As a generation source thereof, for example, an excimer laser has been put into practical use as one that outputs high energy in a short wavelength region. According to the excimer laser, ablation is caused only in the vicinity of the interface in a very short time, and almost no temperature shock is given to the base 50 and the alignment film 51.
[0091]
The surface of the alignment film 51 peeled off from the base 50 is preferably subjected to a cleaning process to remove a portion deteriorated by the radiation 60. Note that irradiation of the radiation 60 may be omitted if the base 50 and the alignment film 51 are easily peeled from each other.
[0092]
As described above, the microlens array 70 with the alignment film (and the transparent electrode film) can be obtained. When applied to a liquid crystal panel, the alignment film 51 is subjected to a rubbing process in order to form grooves (alignment grooves) for aligning liquid crystal molecules in a predetermined direction.
[0093]
According to the present embodiment, since the alignment film 52 is formed on the base 50 in advance, the firing temperature to the light transmissive layer 40 (microlens array in a general sense) reinforced by the reinforcing plate 44. There is no damage due to. Moreover, since the light transmissive layer 40 is not exposed to the high temperature at the time of baking, the freedom degree of material selection increases.
[0094]
(Second Embodiment)
FIG. 7A to FIG. 11 are diagrams for explaining a second embodiment of the present invention.
[0095]
First, as shown in FIG. 7A, a first master 110 and a second master 120 are prepared. A plurality of curved surface portions 112 are formed on the first master 110, and each curved surface portion 112 has a concave shape so as to be a reverse pattern of a convex curved surface. On the other hand, a plurality of convex portions 122 are formed on the second master 120. The plurality of convex portions 122 have a black matrix shape in plan view.
[0096]
The first and second masters 110 and 120 are disposed so that the curved surface portions 112 and the convex portions 122 face each other, and the convex portions 122 face each other between the curved surface portions 112.
[0097]
Then, the master 110 and the master 120 are brought into close contact via the first light-transmitting layer precursor 130. The first light transmissive layer precursor 130 is a material for the first light transmissive layer 132 shown in FIG. In FIG. 7A, the master 110 is located below, but the master 120 may be located below.
[0098]
The light transmissive layer precursor 130 can be selected from materials that can be selected as the light transmissive layer precursor 38 of the first embodiment.
[0099]
Then, as shown in FIG. 7B, the light transmissive layer precursor 130 is expanded to a predetermined region. A predetermined pressure may be applied to at least one of the masters 110 and 120 as necessary. Here, the light transmissive layer precursor 130 is dropped on the master 110, but may be dropped on the master 120 or may be dropped on both the masters 110 and 120. Further, the light-transmitting layer precursor 130 is applied to one or both of the masters 110 and 120 by using a spin coating method, a dipping method, a spray coating method, a roll coating method, a bar coating method, or the like. May be.
[0100]
Further, if the light transmissive layer precursor 130 is, for example, an ultraviolet curable resin, as shown in FIG. 7C, a predetermined amount of ultraviolet light 140 is irradiated from at least one of the masters 110 and 120 to transmit light. The functional layer precursor 130 is cured. In this case, it is necessary that the master on the side irradiated with ultraviolet rays has ultraviolet transparency.
[0101]
Thus, the first light transmissive layer 132 is formed between the masters 110 and 120. Since a plurality of lenses 134 transferred from the plurality of curved surface portions 112 are formed on one surface of the light transmissive layer 132, in general, this may be referred to as a microlens array. A plurality of concave portions 136 transferred from the plurality of convex portions 122 are formed on the other surface of the light transmissive layer 132. The plurality of recesses 136 have a black matrix shape in a plan view (not shown). Note that the recess 136 is formed between the lenses 134.
[0102]
Then, as shown in FIG. 8A, the master 120 is peeled off from the light-transmitting layer 132, and the concave portion 136 transferred from the convex portion 122 is opened.
[0103]
Next, as illustrated in FIG. 8B, the light-shielding material 142 is filled in the concave portion 136 of the light-transmitting layer 132 to form the light-shielding layer 138. The light shielding layer 138 becomes a black matrix.
[0104]
As the light-shielding material 142, various materials can be applied as long as they are materials that do not transmit light and have durability. For example, a material obtained by dissolving a black dye or a black pigment in a solvent together with a binder resin is used as the light shielding material 142. The solvent is not particularly limited to the type, and water or various organic solvents can be applied. Examples of the organic solvent include propylene glycol monomethyl ether acetate, propylene glycol monopropyl ether, methoxymethyl propionate, ethoxyethyl propionate, ethyl cellosolve, ethyl cellosolve acetate, ethyl lactate, ethyl pyruvate, methyl amyl ketone, and cyclohexanone. , Xylene, toluene, butyl acetate, and the like can be used.
[0105]
A method of filling the light-shielding material 142 into the recess 136 is not particularly limited, but an ink jet method is suitable. According to the ink jet system, it is possible to economically fill ink at high speed without waste by applying a technique that has been put to practical use for an ink jet printer.
[0106]
FIG. 8B shows a state in which the light shielding material 142 is filled in the recess 136 by the ink jet head 144. Specifically, the inkjet head 144 is disposed so as to face the recess 136, and each light shielding material 142 is discharged to each recess 136.
[0107]
The ink-jet head 144 is practically used for an ink-jet printer, for example. The ink-jet head 144 is a piezo jet type that discharges ink by applying a pressure to the ink by using a volume change of the piezoelectric element, or an electrothermal transducer as an energy generating element. A type in which the volume of ink is expanded or vaporized and ink is ejected with the pressure can be used, and the ejection area and ejection pattern can be set arbitrarily.
[0108]
In the present embodiment, the light shielding material 142 is discharged from the inkjet head 144. Therefore, the light-shielding material 142 needs to ensure fluidity in order to enable ejection from the inkjet head 144.
[0109]
When the light shielding material 142 is filled, the driving position is controlled by controlling the ink jet head 144 so as to fill the concave portion 136 formed in the light transmissive layer 132 with a uniform amount. When the light-shielding material 142 is uniformly filled to every corner of the recess 136, the filling is completed. When a solvent component is contained, the solvent component is removed from the light-shielding material 142 by heat treatment. Since the light-shielding material 142 contracts when the solvent component is removed, it is necessary to fill the thickness that can secure the necessary light-shielding property with an amount that remains even after shrinkage.
[0110]
Next, as illustrated in FIG. 9A, an adhesive layer precursor 146 is dropped on the light transmissive layer 132. The adhesive layer precursor 146 can be selected from materials that can be used as the adhesive layer precursor 56 of the first embodiment. Then, the base 148 on which the transparent electrode film 150 and the alignment film 151 are previously formed is brought into close contact with the adhesive layer precursor 146, and the adhesive layer precursor 146 is expanded. The formation of the transparent electrode film 150 and the alignment film 151 is the same as the transparent electrode film 52 and the alignment film 51 of the first embodiment. The base 148 can be selected from materials that can be used as the base 50 of the first embodiment.
[0111]
The adhesive layer precursor 146 may be spread on the light-transmitting layer 132 or the base 148 by a method such as a spin coating method or a roll coating method, and then the base 148 may be adhered.
[0112]
Thus, the adhesive layer precursor 146 adheres the transparent electrode film 150 on the alignment film 151 formed on the base 148 and the surface of the light transmissive layer 132 on which the light shielding layer 138 is formed. It becomes.
[0113]
Subsequently, as illustrated in FIG. 9C, the master 110 is peeled from the light transmissive layer 132. Since the lens 134 is formed on the light transmissive layer 132 by the curved surface portion 112 of the master 110, it is generally called a microlens array. However, in the present application, at least the alignment film 151 is formed. What is possessed is defined as a microlens array.
[0114]
Next, as shown in FIG. 10A, the surface of the light transmissive layer 132 having the lens 134 and the reinforcing plate 154 are brought into close contact with each other through the second light transmissive layer precursor 152. The process is the same as the process shown in FIG. 9A, and the second light transmissive layer precursor 152 can be selected from materials that can be selected as the first light transmissive layer precursor 130.
[0115]
The reinforcing plate 154 is used to reinforce the microlens array, and has characteristics such as process resistance required in the microlens array manufacturing process and mechanical strength required as the microlens array. If satisfied, the reinforcing plate 154 is unnecessary.
[0116]
Then, as shown in FIG. 10B, radiation 60 is applied to the interface between the alignment film 151 and the base 148 through the base 148, and the base 148 is peeled off as shown in FIG. Note that irradiation with the radiation 60 may be omitted as long as the base 148 and the alignment film 151 are easily separated from each other.
[0117]
Thus, as shown in FIG. 11, a microlens array 160 in which the alignment film 151 (and the transparent electrode film 150) is formed is obtained. When applied to a liquid crystal panel, the alignment film 151 is subjected to a rubbing process in order to form grooves (alignment grooves) for aligning liquid crystal molecules in a predetermined direction.
[0118]
According to the present embodiment, the first and second masters 110 and 120 are brought into close contact with each other via the first light-transmitting layer precursor 130, and the curved surface portion 112 of the first master 110 is transferred to transfer the lens 134. Form. Thus, the first light transmissive layer 132 having the plurality of lenses 134 can be easily manufactured. According to this manufacturing method, the material use efficiency is high, the number of steps can be shortened, and the cost can be reduced. Further, once manufactured, the first and second masters 110 and 120 can be used any number of times as long as the durability permits, and therefore can be omitted in the manufacturing process of the second and subsequent microlens arrays. Reduction and cost reduction can be achieved.
[0119]
Further, a concave portion 136 is transferred and formed on the light transmissive layer 132 by the convex portion 122 of the second master 120, and the concave portion 136 is filled with a light shielding material 142. The light shielding layer 138 made of the light shielding material 142 forms a black matrix and can improve the contrast between pixels.
[0120]
According to this embodiment, in addition to eliminating damage to the first and second light transmissive layers 132 and 156 due to the firing temperature at the time of forming the alignment film, the microlens array that can improve contrast is transferred. It can be easily manufactured by the method.
[0121]
(Third embodiment)
FIG. 12A to FIG. 13C are diagrams for explaining a third embodiment of the present invention.
[0122]
In the first embodiment described above, a microlens array having a convex lens is manufactured. However, when manufacturing a microlens array having a concave lens, the curved surface portion 19 of the master 10 is made concave. is required.
[0123]
Further, in the first embodiment, the duplicate disc 30 is manufactured from the master disc 10 via the intermediate disc 24, but it is also possible to manufacture the duplicate disc directly from the master disc. In this case, in order to manufacture a microlens array having a convex lens as in the first embodiment, a master having a convex curved surface is prepared, and a replica having a concave curved surface is manufactured from the master. is required.
[0124]
Therefore, the present embodiment relates to a method for forming a master having a convex curved surface portion.
[0125]
First, as illustrated in FIG. 12A, a resist layer 214 is formed over a substrate 212. About this process and the material of the board | substrate 212 and the resist layer 214, it is the same as that of 1st Embodiment (refer FIG. 1 (A)).
[0126]
Next, as shown in FIG. 12B, a mask 216 is placed over the resist layer 214, and only a predetermined region of the resist layer 214 is exposed to the radiation 218 through the mask 216. The mask 216 is patterned so that the radiation 218 is transmitted only in a region necessary for forming the curved surface portion 219 shown in FIG.
[0127]
Then, when the resist layer 214 is exposed to the radiation 218 and developed under predetermined conditions, only the resist layer 214 in the exposed region 217 of the radiation 218 is selectively removed as shown in FIG. The surface of the substrate 212 is exposed, and the other region remains covered with the resist layer 214.
[0128]
When the resist layer 214 is thus patterned, the resist layer 214 is heated in a reflow process. When the resist layer 214 is melted by heat, the surface of the resist layer 214 has a curved shape as shown in FIG. 12D due to surface tension.
[0129]
Subsequently, as shown in FIG. 12E, the substrate 212 is etched to a predetermined depth by the etchant 220 using the resist layer 214 as a mask. Specifically, anisotropic etching, for example, dry etching such as reactive ion etching (RIE) is performed.
[0130]
FIGS. 13A to 13C are diagrams illustrating a process of etching a substrate. The substrate 212 is partially covered with a resist layer 214 having a curved surface shape. The substrate 212 is first etched in a region not covered with the resist layer 214. Then, the resist layer 214 is etched by the etchant 220 and gradually becomes smaller from the region indicated by the two-dot chain line to the region indicated by the solid line, as shown in FIGS. 13 (A) and 13 (B). Here, since the resist layer 214 has a curved shape, the substrate 212 is gradually exposed when the resist layer 214 of this shape is gradually reduced, and the exposed region is gradually and gradually etched. Go. Thus, since the substrate 212 is continuously and gradually etched, the surface shape of the substrate 212 after etching becomes a curved surface. Finally, as shown in FIG. 13C, a convex curved surface portion 219 is formed on the substrate 212, and the master 210 is obtained.
[0131]
The master 210 is economical because once it is manufactured, it can be used as many times as the durability permits. Further, the manufacturing process of the master disk 210 can be omitted in the manufacturing process of the second and subsequent microlens arrays, and the number of processes can be reduced and the cost can be reduced.
[0132]
(Fourth embodiment)
FIG. 14 to FIG. 15B are diagrams for explaining a fourth embodiment of the present invention. As shown in FIG. 14, in this embodiment, the master 10 used in the first embodiment, the base 50 on which the light-shielding layer 54, the transparent electrode film 52, and the alignment film 51 are formed, and the light transmitting property. Layer precursor 38 is used. Then, the side of the master disk 10 on which the curved surface portion 19 is formed and the side of the base 50 on which the light-shielding layer 54 and the like are formed face each other, and both are disposed via the light-transmitting layer precursor 38. Adhere closely.
[0133]
Thus, as shown in FIG. 15A, the light transmissive layer 310 is formed between the base 50 and the master 10. A plurality of convex lenses 312 are formed on the light transmissive layer 310 corresponding to the curved surface portion 19 of the master 10.
[0134]
Then, as shown in FIG. 15B, the alignment film 51 (and the transparent electrode film 52) is formed by peeling the master 10 from the light transmissive layer 310 and peeling the base 50 from the alignment film 51. A microlens array 300 is obtained. When applied to a liquid crystal panel, the alignment film 51 is subjected to a rubbing process in order to form grooves (alignment grooves) for aligning liquid crystal molecules in a predetermined direction. Note that the peeling step is the same as in the first embodiment.
[0135]
According to the present embodiment, the light transmissive layer 310 is bonded to the alignment film 51 while being formed on the base 50 from the light transmissive layer precursor 38. Therefore, the overall process can be shortened. Here, after peeling off the light-transmitting layer 310 from the master 10, a second light-transmitting layer, a reinforcing plate, or the like may be provided on the light-transmitting layer 310 as necessary. Further, similarly to the first embodiment, it is possible to prevent damage to the light transmissive layer 310 due to the firing temperature.
[0136]
(Fifth embodiment)
FIG. 16 to FIG. 17C are diagrams for explaining a fifth embodiment of the present invention. This embodiment is a modification of the first embodiment, and as shown in FIG. 16, a separation layer 320 is formed between the base 50 and the alignment film 51. That is, the separation layer 320 is first formed on the base 50, and then the alignment film 51 is formed on the separation layer 320, and the transparent electrode film 52 is formed thereon. Other configurations are the same as those of the first embodiment.
[0137]
When the separation layer 320 is irradiated with the radiation 60 through the base 50, the base 50 and the transparent electrode 52 are easily peeled off.
[0138]
Examples of the material constituting the separation layer 320 include various oxide ceramics such as amorphous silicon, silicon oxide, silicate compound, titanium oxide, titanate compound, zirconium oxide, zircon oxide, lanthanum oxide, and lanthanate compound, (Strong) Dielectric or semiconductor, nitride ceramics such as silicon nitride, aluminum nitride, titanium nitride, organic polymer materials such as acrylic resin, epoxy resin, polyamide, polyimide, Al, Li, Ti, Mn, In, Sn , Y, La, Ce, Nd, Pr, Gd, Sm, or one or more alloys selected from Sm can be used. From among these, it is appropriately selected according to the process conditions, the material of the base 50, the alignment film 51 and the transparent electrode film 52, and the like.
[0139]
The formation method of the separation layer 320 is not particularly limited, and is appropriately selected according to the composition and the formed film thickness. Specifically, for example, various vapor phase growth methods such as CVD, vapor deposition, sputtering, ion plating, electroplating, electroless plating, Langmuir-Blodget (LB) method, spin coating method, dipping method, spray coating method, A roll coat method, a bar code method or the like is used.
[0140]
If the thickness of the separation layer 320 is too thin, damage to the alignment film 51 is increased. On the other hand, if the thickness is too thick, the energy amount of the radiation 46 necessary to ensure good peelability of the separation layer 320 must be increased. Don't be. Therefore, although the thickness of the separation layer 320 varies depending on the purpose of peeling and the composition, it is usually preferably about 1 nm to 20 μm, more preferably about 10 nm to 10 μm, and most preferably about 40 nm to 1 μm. Note that the thickness of the separation layer 320 is preferably as uniform as possible.
[0141]
When such a separation layer 320 is irradiated with radiation 60 as shown in FIG. 16, the separation from the base 50 becomes possible. There are three types of peeling modes as shown in FIGS. 17 (A) to 17 (C).
[0142]
FIG. 17A shows an example in which the bonding force at the interface between the base 50 and the separation layer 320 is reduced and peeling occurs at the interface between the two. In this case, in order to remove the separation layer 320 from the alignment film 51, it is preferable to perform a peeling (cleaning) process.
[0143]
FIG. 17B shows an example in which the bonding force at the interface between the alignment film 51 and the separation layer 320 is reduced and peeling occurs at the interface between the two. Even in this case, since a part of the separation layer 320 may adhere to the alignment film 51, it is preferable to perform a cleaning process on the surface of the alignment film 51.
[0144]
FIG. 17C illustrates an example in which separation occurs due to a reduction in the bonding force between molecules or atoms inside the separation layer 320. Even in this case, it is preferable to perform a cleaning process in order to remove the debris of the separation layer 320 from the alignment film 51.
[0145]
(Sixth embodiment)
FIG. 18A to FIG. 18C are diagrams for explaining a sixth embodiment of the present invention. This embodiment is a modification of the first embodiment, and is a manufacturing method that can omit the rubbing process.
[0146]
In the present embodiment, as shown in FIG. 18A, a base 330 on which a streak-like protrusion 331 is formed is used. The protrusions 331 form a reverse pattern of grooves (alignment grooves) formed in the alignment film by a conventional rubbing process. Then, a polyimide resin or the like is provided on the base 330 and is baked to form the alignment film 332. Subsequently, as shown in FIG. 18B, a transparent electrode film 52 is formed over the alignment film 332.
[0147]
Then, through the same process as shown in FIGS. 5C to 6C, a microlens array 350 shown in FIG. 18C is obtained. The microlens array 350 has an alignment film 332, and alignment grooves 333 are formed in the alignment film 332 corresponding to the protrusions 331 of the base 330.
[0148]
According to the present embodiment, since the alignment groove 333 for aligning liquid crystal molecules in a predetermined direction can be formed at the same time in the step of forming the alignment film 332, the rubbing process can be omitted.
[0149]
(Seventh embodiment)
FIG. 19 (A) to FIG. 19 (C) are diagrams for explaining a seventh embodiment of the present invention. This embodiment is a modification of the second embodiment, and is a manufacturing method in which a spacer (support member) is integrally formed on an alignment film when a microlens array is used in a liquid crystal panel.
[0150]
In the present embodiment, as shown in FIG. 19A, a base 340 in which a recess 341 is formed is used. Note that the recess 341 is formed by etching or the like. Then, a polyimide resin or the like is provided on the base 340 so as to be filled in the recesses 341, and this is baked to form the alignment film 342. A transparent electrode film 150 is formed over the alignment film 342 as shown in FIG. Then, through steps similar to those shown in FIGS. 7A to 11, a microlens array 370 shown in FIG. 19C is obtained. The microlens array 370 has a spacer 343 formed integrally with the alignment film 342.
[0151]
The depth of the recess 341 corresponds to the height of the spacer 343 and is processed according to the liquid crystal panel to be manufactured. For example, in a VGA type liquid crystal panel using a TFT as a driving element, the depth is about 2 to 6 μm.
[0152]
The depth of the concave portion 341 of the base 340 can be controlled with high accuracy by an etching technique. For example, the etching error is ± 0.05 μm with respect to the depth of the recess 341 of 3 μm. Accordingly, since the height of the spacer 343, that is, the cell gap can be kept constant, it is easy to maintain display characteristics such as light transmittance, contrast ratio, response speed, etc. of the liquid crystal panel at suitable values. .
[0153]
In the present embodiment, it is preferable to arrange the concave portion 341 between the adjacent lenses 134. With this configuration, the spacer 343 can be easily provided between the lenses 134. Therefore, the spacer 343 is not disposed on the lens 134 that collects light, and the manufacturing yield of the microlens array or the liquid crystal panel can be improved.
[0154]
In addition, it is preferable to arrange the concave portion 341 on the light-shielding layer 138 (black matrix). With this configuration, the spacer 343 can be easily provided over the light-shielding layer 138. Accordingly, the spacer 343 is not disposed on the pixel. In addition, by providing the spacer 343 in the light-shielding layer 138, the uneven alignment of the liquid crystal due to the spacer 343, the influence on the polarization characteristics of the liquid crystal panel, and the like can be reduced, and the image quality of the liquid crystal panel can be maintained in a preferable state. it can.
[0155]
The shape of the concave portion 341 can be a columnar shape, a prismatic shape, or the like, and a cylindrical shape is particularly preferable. By forming the spacer 343 in a columnar shape, disorder of the alignment of the liquid crystal can be suppressed.
[0156]
Note that the spacers 343 do not need to be disposed on the light-shielding layer 138 between all adjacent lenses 134 or between all pixels, and may be disposed at an arbitrary position. However, the spacers 343 need to be arranged so as to obtain a required strength in order to keep the cell gap uniform. For example, the arrangement interval of the spacers 343 is preferably in the range of 100 to 200 μm.
[0157]
This embodiment can also be combined with the sixth embodiment described above. That is, a protrusion similar to the protrusion 331 of the base 330 shown in FIG. 18A is formed on the surface of the base 340 where the recess 341 is formed, and an alignment groove is formed in a predetermined region of the alignment film 342. May be.
[0158]
FIG. 20 is a diagram showing a part of a liquid crystal projector to which the microlens array according to the present invention is applied. This liquid crystal projector includes a light valve 400 incorporating the microlens array 70 manufactured by the method according to the first embodiment described above, and a lamp 410 as a light source.
[0159]
The microlens array 70 is arranged so that the lens 42 is concave when viewed from the lamp 410. A TFT substrate 414 is provided with a gap from the alignment film 51. The TFT substrate 414 is provided with transparent individual electrodes 416 and thin film transistors 418, and an alignment film 420 is formed thereon. The TFT substrate 414 is disposed with the alignment film 420 facing the alignment film 51.
[0160]
A liquid crystal 430 is sealed between the alignment films 51 and 420, and the liquid crystal 430 is driven by a voltage controlled by the thin film transistor 418.
[0161]
According to this liquid crystal projector, the light 440 emitted from the lamp 410 is condensed by the lens 42 for each pixel, so that a bright screen can be displayed.
[0162]
As a premise, the light refractive index na of the adhesive layer 58 and the light refractive index nb of the light transmissive layer 40 are:
na <nb
It is necessary to be in the relationship. By satisfying this condition, light enters from a medium having a high refractive index to a medium having a low refractive index, and the light 440 is refracted and condensed away from the normal line of the interface between the two media. And the screen can be brightened.
[0163]
FIG. 21 is a diagram showing a part of a liquid crystal projector to which the microlens array according to the present invention is applied. This liquid crystal projector has a light valve 500 incorporating a microlens array 160 manufactured by the method according to the second embodiment described above, and a lamp 410 as a light source.
[0164]
The microlens array 160 is arranged so that the lens 134 is convex when viewed from the lamp 410. Further, a TFT substrate 414 is provided with a gap from the alignment film 151. The TFT substrate 414 is provided with transparent individual electrodes 416 and thin film transistors 418, and an alignment film 420 is formed thereon. The TFT substrate 414 is disposed with the alignment film 420 facing the alignment film 151.
[0165]
A liquid crystal 430 is sealed between the alignment films 151 and 420, and the liquid crystal 430 is driven by a voltage controlled by the thin film transistor 418.
[0166]
According to this liquid crystal projector, the light 440 emitted from the lamp 410 is condensed by the lens 134 for each pixel, so that a bright screen can be displayed.
[0167]
As a premise, the light refractive index na ′ of the first light transmissive layer 132 and the light refractive index nb ′ of the second light transmissive layer 156 are:
na '>nb'
It is necessary to be in the relationship. By satisfying this condition, light enters from a medium having a low refractive index to a medium having a high refractive index, and the light 440 is refracted and condensed so as to approach the normal line of the interface between the two media. And the screen can be brightened.
[0168]
[Brief description of the drawings]
FIG. 1A to FIG. 1E are diagrams illustrating a process for manufacturing a master disk according to a first embodiment.
FIG. 2A to FIG. 2C are diagrams showing a process for manufacturing an intermediate disc from a master disc in the first embodiment.
FIGS. 3A to 3C are diagrams showing a process of manufacturing a replica disk from an intermediate disk in the first embodiment.
FIGS. 4A to 4C are diagrams illustrating a process of manufacturing the microlens array according to the first embodiment. FIGS.
FIGS. 5A to 5C are views showing a process for manufacturing the microlens array according to the first embodiment. FIGS.
FIGS. 6A to 6C are diagrams illustrating a process of manufacturing the microlens array according to the first embodiment. FIGS.
FIGS. 7A to 7C are views showing a method for manufacturing a microlens array according to the second embodiment. FIGS.
FIGS. 8A and 8B are diagrams illustrating a method for manufacturing a microlens array according to the second embodiment. FIGS.
FIG. 9A to FIG. 9C are views showing a method for manufacturing a microlens array according to the second embodiment.
FIGS. 10A and 10B are views showing a method for manufacturing a microlens array according to the second embodiment. FIGS.
FIG. 11 is a diagram illustrating a manufacturing method of the microlens array according to the second embodiment.
FIGS. 12A to 12E are views showing a method of manufacturing a master according to the third embodiment.
FIGS. 13A to 13C are views showing an etching process in the third embodiment.
FIG. 14 is a diagram illustrating a method for manufacturing a microlens array according to a fourth embodiment.
FIGS. 15A and 15B are views showing a method for manufacturing a microlens array according to the fourth embodiment. FIGS.
FIG. 16 is a diagram showing a method for manufacturing a microlens array according to a fifth embodiment.
FIGS. 17A to 17C are views showing a method for manufacturing a microlens array according to the fifth embodiment. FIGS.
FIGS. 18A to 18C are views showing a method of manufacturing a microlens array according to the sixth embodiment. FIGS.
FIGS. 19A to 19C are views showing a method for manufacturing a microlens array according to the seventh embodiment. FIGS.
FIG. 20 is a diagram illustrating an electronic apparatus including a microlens array to which the present invention is applied.
FIG. 21 is a diagram illustrating an electronic apparatus including a microlens array to which the present invention is applied.
[Explanation of symbols]
38 Light transmissive layer precursor
40 Light transmissive layer
42 lenses
50 base
51 Alignment film
60 radiation
70 Micro lens array
138 Light-shielding layer
142 Light-shielding material
320 Separation layer
331 protrusion
333 Orientation groove
341 recess
343 Spacer (support member)

Claims (14)

A first step of forming an alignment film on a base , comprising firing the alignment film ;
A second step of providing a light transmissive layer having a plurality of lenses on the alignment film after firing the alignment film ;
A third step of peeling the alignment film integrally with the light-transmitting layer from the base;
A method of manufacturing a microlens array including: In the manufacturing method of the micro lens array of Claim 1,
Before the second step, including the step of forming the light transmissive layer separately from the alignment film,
A method of manufacturing a microlens array, wherein the completed light transmissive layer is bonded to the alignment film in the second step. In the manufacturing method of the micro lens array of Claim 1,
A method for producing a microlens array, wherein in the second step, a light transmissive layer is formed on the base while adhering to the alignment film from a light transmissive layer precursor. In the manufacturing method of the micro lens array in any one of Claims 1-3,
The base has radiation transparency,
A method of manufacturing a microlens array, wherein, in the third step, the alignment film is irradiated with the radiation through the base to reduce a binding force at an interface between the alignment film and the base. In the manufacturing method of the micro lens array in any one of Claims 1-3,
In the first step, a separation layer is previously formed on the base, and the alignment film is formed on the separation layer,
The base has radiation transparency,
A method of manufacturing a microlens array, wherein, in the third step, the separation layer is irradiated with the radiation through the base to reduce a binding force at an interface between the base and the separation layer. In the manufacturing method of the micro lens array in any one of Claims 1-3,
In the first step, a separation layer is previously formed on the base, and the alignment film is formed on the separation layer,
The base has radiation transparency,
A method of manufacturing a microlens array, wherein, in the third step, the separation layer is irradiated with the radiation through the base to reduce a bonding force at an interface between the alignment film and the separation layer. In the manufacturing method of the micro lens array in any one of Claims 1-3,
In the first step, a separation layer is previously formed on the base, and the alignment film is formed on the separation layer,
The base has radiation transparency,
A method of manufacturing a microlens array, wherein, in the third step, the separation layer is irradiated with the radiation through the base to reduce a bonding force inside the separation layer. In the manufacturing method of the micro lens array of Claim 4,
A method of manufacturing a microlens array, comprising a step of cleaning the surface of the alignment film after the third step. In the manufacturing method of the micro lens array in any one of Claims 5-7,
A method of manufacturing a microlens array including a step of removing the separation layer attached to the surface of the alignment film after the third step. In the manufacturing method of the micro lens array in any one of Claims 1-9,
At least one recess is formed on the surface of the base,
In the first step, the concave portion of the base is filled with the material of the alignment film to form a convex portion integrated with the alignment film,
The convex portion is a method of manufacturing a microlens array that serves as a support member for maintaining a constant interval for enclosing liquid crystal in the liquid crystal panel. In the manufacturing method of the micro lens array of Claim 10,
The recess is formed in a region corresponding to the space between the lenses on the base,
The method of manufacturing a microlens array, wherein the second step is performed by positioning the concave portion of the base between the lenses. In the manufacturing method of the microlens array in any one of Claims 1, 2, 3, 4, 10 or 11,
In a predetermined region on the surface of the base, a protrusion corresponding to the alignment groove formed in the alignment film is formed,
A method of manufacturing a microlens array, wherein the alignment groove is formed in a predetermined region of the alignment film in the first step. In the manufacturing method of the micro lens array in any one of Claims 1-12,
Forming a transparent electrode film on one of the alignment film and the light transmissive layer,
In the second step, the method for manufacturing a microlens array, wherein the light-transmissive layer is provided on the alignment film via the transparent electrode film. The method of manufacturing a microlens array according to claim 13,
A method of manufacturing a microlens array, wherein the transparent electrode film is formed on the alignment film.

Images