Light-condensing film, liquid-crystal panel and backlight as well as manufacturing process for light-condensing film
A conventional liquid crystal display comprises a number of components, so that a manufacturing cost cannot be reduced. Furthermore, a large-area substrate has problems in shipping. According to this invention, a liquid-crystal panel is prepared by forming individual optically functional films, a TFT device and a light-emitting device on a long thin film and then laminating the film by a transfer process. A base film to be a substrate in a liquid-crystal panel preferably has a thickness of 10 μm to 200 μm, a curvature radius of 40 mm or less as a measure of flexibility and a coefficient of thermal expansion of 50 ppm/° C. or less. Furthermore, it more preferably gives a variation of ±5% or less in mechanical and optical properties to a thermal history at 200° C.
1. A process for manufacturing a light-condensing layered film,
the light-condensing layered film comprising
a light-condensing film and a long light-guiding film, the light-condensing film comprising an array of light collectors, the array of light collectors comprising an organic resin, the array of light collectors being disposed on a long light-diffusing film with a flexibility of 40 mm or less of a curvature radius and a coefficient of thermal expansion of 50 ppm/.degree. C. or less; the array of light collectors comprising a first surface and a second surface opposed to the first surface, the second surface contacting the long light diffusing film, the first surface being flat and having a smaller area than the second surface; wherein the long light-guiding film is laminated on the surface facing the light diffusing film in the light collector in the light-condensing film;
the process comprising the steps of:
filling a first irregularity in a support corresponding to a second irregularity for the array of light collectors with the organic resin to form the second irregularity made of the organic resin for the array of light collectors;
transferring the second irregularity made of the organic resin from the support to the long light-diffusing thin film to form the array of light collectors, the array of light collectors; and
laminating the long light-guiding film on the second surface of the array of light collectors exposing the second irregularity.
2. The process for manufacturing a light-condensing layered film as claimed in claim 1 , wherein the transferring step comprises curing the organic resin in the form of the first irregularity under pressure.