Retardation film, method of manufacturing the same, and display
A retardation film which is manufacturable by a simple process, and being capable of preventing a decline in light use efficiency is provided. A retardation film includes: a substrate having a plurality of grooves extending in a specific direction on a surface thereof; and a retardation layer arranged in contact with the surface of the substrate, and including a liquid crystal material, the liquid crystal material being aligned along the extending direction of the plurality of grooves and being polymerized.
1. A method of manufacturing a retardation film comprising the steps of:
forming a metal mold in which a stripe-shaped pattern having a plurality of projections and depressions extending in a direction orthogonal to a polarization direction of a laser beam and crossing a scanning direction is drawn by irradiating a linear polarization laser beam to a surface of a base made of a metal material with the use of a femtosecond laser;
forming a plurality of grooves extending in a specific direction on a surface of a substrate with the use of the metal mold;
coating the surface on which the plurality of grooves are formed of the substrate with a liquid crystal material having polymerizability so that the liquid crystal material is arranged in contact with the surface of the substrate; and
polymerizing the liquid crystal material, wherein a pattern formed by the plurality of grooves has a periodic structure, and the periodic structure has a spread of approximately 2 to 10% in pitches of projections and depressions, and a spread of approximately 3 to 8% in angles of projections and depressions.
2. The method of manufacturing a retardation film according to claim 1
wherein
the metal mold is made of SUS or NiP.
3. The method of manufacturing a retardation film according to claim 1
wherein
the metal mold is made of SUS or NiP.
4. The method of manufacturing a retardation film according to claim 1 , wherein
the formation of the plurality of grooves using the metal mold is performed by thermal transfer or transfer using a 2P molding method.
5. The method of manufacturing a retardation film according to claim 1 , wherein
the formation of the plurality of grooves using the metal mold is performed by thermal transfer or transfer using a 2P molding method.
6. The method of manufacturing a retardation film according to claim 2 , wherein
the formation of the plurality of grooves using the metal mold is performed by thermal transfer or transfer using a 2P molding method.
7. The method of manufacturing a retardation film according to claim 1 , wherein
the metal mold includes a plurality of first grooves extending in a first direction and a plurality of second grooves extending in a second direction orthogonal to the first direction, and
first groove regions including the plurality of first grooves and second groove regions including the plurality of second grooves each have a stripe shape, and are alternately arranged.
8. The method of manufacturing a retardation film according to claim 1 , wherein
the metal mold includes a plurality of first grooves extending in a first direction and a plurality of second grooves extending in a second direction orthogonal to the first direction, and
first groove regions including the plurality of first grooves and second groove regions including the plurality of second grooves each have a stripe shape, and are alternately arranged.
9. The method of manufacturing a retardation film according to claim 2 , wherein
the metal mold includes a plurality of first grooves extending in a first direction and a plurality of second grooves extending in a second direction orthogonal to the first direction, and
first groove regions including the plurality of first grooves and second groove regions including the plurality of second grooves each have a stripe shape, and are alternately arranged.
10. The method of manufacturing a retardation film according to claim 3 , wherein
the metal mold includes a plurality of first grooves extending in a first direction and a plurality of second grooves extending in a second direction orthogonal to the first direction, and
first groove regions including the plurality of first grooves and second groove regions including the plurality of second grooves each have a stripe shape, and are alternately arranged.
11. The method of manufacturing a retardation film according to claim 1 , wherein
the substrate is made of a plastic material.
12. The method of manufacturing a retardation film according to claim 1 , wherein
the substrate is made of a plastic material.
13. The method of manufacturing a retardation film according to claim 2 , wherein
the substrate is made of a plastic material.
14. The method of manufacturing a retardation film according to claim 3 , wherein
the substrate is made of a plastic material.
15. The method of manufacturing a retardation film according to claim 4 , wherein
the substrate is made of a plastic material.
16. The method of manufacturing a retardation film according to claim 1 , wherein
the substrate is made of a base including a resin layer formed on a surface thereof.
17. The method of manufacturing a retardation film according to claim 1 , wherein
the substrate is made of a base including a resin layer formed on a surface thereof.
18. The method of manufacturing a retardation film according to claim 2 , wherein
the substrate is made of a base including a resin layer formed on a surface thereof.
19. The method of manufacturing a retardation film according to claim 3 , wherein
the substrate is made of a base including a resin layer formed on a surface thereof.
20. The method of manufacturing a retardation film according to claim 4 , wherein
the substrate is made of a base including a resin layer formed on a surface thereof.
21. The method of manufacturing a retardation film according to claim 5 , wherein
the substrate is made of a base including a resin layer formed on a surface thereof.
22. The method of manufacturing a retardation film according to claim 1 , wherein
the surface on which the plurality of grooves are formed of the substrate is coated with the liquid crystal material, and then a heating process is performed on the liquid crystal material at a temperature equal to or higher than a phase transition temperature between a liquid crystal phase and an isotropic phase of the liquid crystal material.
23. The method of manufacturing a retardation film according to claim 1 , wherein
the surface on which the plurality of grooves are formed of the substrate is coated with the liquid crystal material, and then a heating process is performed on the liquid crystal material at a temperature equal to or higher than a phase transition temperature between a liquid crystal phase and an isotropic phase of the liquid crystal material.
24. The method of manufacturing a retardation film according to claim 2 , wherein
the surface on which the plurality of grooves are formed of the substrate is coated with the liquid crystal material, and then a heating process is performed on the liquid crystal material at a temperature equal to or higher than a phase transition temperature between a liquid crystal phase and an isotropic phase of the liquid crystal material.
25. The method of manufacturing a retardation film according to claim 3 , wherein
the surface on which the plurality of grooves are formed of the substrate is coated with the liquid crystal material, and then a heating process is performed on the liquid crystal material at a temperature equal to or higher than a phase transition temperature between a liquid crystal phase and an isotropic phase of the liquid crystal material.
26. The method of manufacturing a retardation film according to claim 4 , wherein
the surface on which the plurality of grooves are formed of the substrate is coated with the liquid crystal material, and then a heating process is performed on the liquid crystal material at a temperature equal to or higher than a phase transition temperature between a liquid crystal phase and an isotropic phase of the liquid crystal material.
27. The method of manufacturing a retardation film according to claim 5 , wherein
the surface on which the plurality of grooves are formed of the substrate is coated with the liquid crystal material, and then a heating process is performed on the liquid crystal material at a temperature equal to or higher than a phase transition temperature between a liquid crystal phase and an isotropic phase of the liquid crystal material.
28. The method of manufacturing a retardation film according to claim 6 , wherein
the surface on which the plurality of grooves are formed of the substrate is coated with the liquid crystal material, and then a heating process is performed on the liquid crystal material at a temperature equal to or higher than a phase transition temperature between a liquid crystal phase and an isotropic phase of the liquid crystal material.