Forming film, laminate, laminate with light guide layer, lighting device, and mold

Abstract

To reduce luminance unevenness. The present shaped film is an optical shaped film having a main face, a plurality of recesses arranged in a formation direction with a first period P1 and a plurality of protrusions arranged in the formation direction with a second period P2 are provided on the main face, a maximum depth of the recesses is greater than a maximum height of the protrusions, when n is a positive integer, either one of n-0.05 ≤ P1 / P2 ≤ n+0.05 or n-0.05 ≤ P2 / P1 ≤ n+0.05 is satisfied.

Description

Technical Field

[0001] This invention relates to shaped films, laminates, laminates with light guide layers, lighting devices, and molds. Background Technology

[0002] For example, Patent Document 1 discloses a transparent substrate having multiple recesses or protrusions formed on a main surface.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: International Publication No. 2019 / 102959 Summary of the Invention

[0006] The technical problem that the invention aims to solve

[0007] However, when light is directed into the interior of the shaped film such as the transparent substrate described in Patent Document 1, sometimes the light extracted from the main surface of the shaped film produces uneven brightness.

[0008] The purpose of this invention is to reduce uneven brightness.

[0009] Technical solutions for solving technical problems

[0010] The shaping film of one aspect of the present invention is an optical shaping film having a main surface, wherein a plurality of recesses arranged in a forming direction with a first period P1 and a plurality of protrusions arranged in the forming direction with a second period P2 are provided on the main surface, the maximum depth of the recesses is greater than the maximum height of the protrusions, and when n is set as a positive integer, either n-0.05≤P1 / P2≤n+0.05 or n-0.05≤P2 / P1≤n+0.05 is satisfied.

[0011] Invention Effects

[0012] According to the present invention, uneven brightness can be reduced. Attached Figure Description

[0013] Figure 1 This is a schematic top view showing a first example of an illumination device with a shaped film according to an embodiment.

[0014] Figure 2 yes Figure 1 A schematic cross-sectional view of line II-II in the diagram.

[0015] Figure 3 Is with Figure 1 A schematic cross-sectional view of the shaped film corresponding to line III-III in the diagram.

[0016] Figure 4This is a schematic cross-sectional view of a mold used to illustrate the manufacturing method of the shaped film.

[0017] Figure 5 This is a schematic cross-sectional view of a mold used to manufacture shaped films.

[0018] Figure 6 This is a schematic cross-sectional view of the mold cavity provided by the shaping film in the embodiment.

[0019] Figure 7 This is a schematic top view showing a first example of the mold cavity provided by the shaping film of the embodiment.

[0020] Figure 8 This is a schematic top view showing a second example of the mold cavity provided by the shaping film of the embodiment.

[0021] Figure 9 This is a schematic top view of a shaped film according to another embodiment and a graph showing the evaluation results of uneven brightness.

[0022] Figure 10 This is a graph showing the brightness distribution of light taken from the main surface of the shaped film in Example 1.

[0023] Figure 11 This is a diagram showing the brightness distribution of light taken from the main surface of the shaped film in Example 3.

[0024] Figure 12 This is a schematic cross-sectional view showing a second example of the shaped film of the embodiment.

[0025] Figure 13 This is a schematic cross-sectional view showing a third example of the shaped film according to the embodiment.

[0026] Figure 14 This is a schematic cross-sectional view showing a fourth example of the shaped film according to the embodiment.

[0027] Figure 15 This is a schematic cross-sectional view showing a second example of an illumination device having a shaped film according to an embodiment. Detailed Implementation

[0028] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the drawings, the same reference numerals are used to denote the same constituent elements, and repeated descriptions are omitted where appropriate.

[0029] The embodiments shown below illustrate shaped films, laminates, laminates with light-guiding layers, lighting devices, and molds used to embody the technical concept of the present invention. The present invention is not limited to the embodiments shown below. Regarding the dimensions, materials, shapes, and relative arrangements of the constituent components described below, unless a specific form is described, it is not intended to limit the scope of the present invention; these are merely examples. Furthermore, the size and positional relationships of the components shown in the accompanying drawings are sometimes exaggerated for clarity.

[0030] In the accompanying figures below, orthogonal coordinates with X, Y, and Z axes are used for orientation. The X, Y, and Z axes are approximately orthogonal to each other. The direction in which the arrow representing the X-axis points is labeled +X direction or +X side, and the direction opposite to +X direction is labeled -X direction or -X side. The direction in which the arrow representing the Y-axis points is labeled +Y direction or +Y side, and the direction opposite to +Y direction is labeled -Y direction or -Y side. The direction in which the arrow representing the Z-axis points is labeled +Z direction or +Z side, and the direction opposite to +Z direction is labeled -Z direction or -Z side.

[0031] The X-direction along the X-axis corresponds to the formation direction in which the plurality of recesses provided in the shaping film of the embodiment are arranged in a first period P1. In the description of the embodiment, the above-mentioned formation direction is referred to as the formation direction X. The Z-direction along the Z-axis represents the direction along the normal to the main surface of the shaping film of the embodiment. In this specification, "top view" means viewing the object from the +Z direction. In addition, the +Z direction is referred to as "up" and the -Z direction is referred to as "down". However, the above-described directional representation is only for illustrative purposes to indicate relative positional relationships and does not limit the direction of the embodiment. Figure 1 and Figure 9 In this context, the X-direction is taken as the formation direction.

[0032] In this specification and claims, "generally parallel" means that the absolute value of the angular offset from a parallel state is 0 degrees or more and 10 degrees or less. "Generally orthogonal" means that the absolute value of the angular offset from an orthogonal state is 0 degrees or more and 10 degrees or less. "Arrangement" is not limited to direct contact, but also includes indirect arrangement, such as via other components. Furthermore, in this specification, "thickness" refers to the length of the object in the Z direction. Additionally, in this specification, cross-sectional views are sometimes shown as end views showing only the cross-section.

[0033] [Implementation Method]

[0034] <Overall structure of the lighting device with the shaped film according to the implementation method>

[0035] Reference Figures 1-5The overall structure of the lighting device with the shaped film according to the embodiment will be described. Figure 1 This is a schematic top view showing a first example of an illumination device 100 equipped with a shaping film 62 according to the embodiment. Figure 2 yes Figure 1 A schematic cross-sectional view of line II-II in the diagram. Figure 3 It means and Figure 1 A schematic cross-sectional view of an example of the shaped film 62 corresponding to line III-III in the diagram. Figure 4 This is a schematic cross-sectional view illustrating an example of a method for manufacturing the shaped film 62. Figure 5 This is a schematic cross-sectional view illustrating an example of a mold used in the manufacture of the shaped film 62.

[0036] like Figure 1 and Figure 2 As shown, the lighting device 100 has a laminate 80 with a light guide layer and a light source LS disposed near the end face 81 of the laminate 80 with the light guide layer. Figure 2 The light source LS shown is positioned to emit light toward the end face 81 of the laminate 80 with the light guide layer. Additionally, in Figure 2 In the example shown, the dashed arrows represent a portion of the light Lr emitted from the light source LS.

[0037] The laminate 80 with a light guide layer includes a light guide layer 10, a laminate 70, and a first adhesive layer 52. The first adhesive layer 52 is disposed between the light guide layer 10 and the laminate 70, and is used to bond the light guide layer 10 and the laminate 70. The laminate 70 includes a substrate 30 and a orientation conversion layer 60. The orientation conversion layer 60 includes a shaping film 62 and a second adhesive layer 54. The second adhesive layer 54 is disposed between the shaping film 62 and the substrate 30, and is used to bond the shaping film 62 and the substrate 30. The substrate 30 and the main surface 621 of the shaping film 62 are arranged opposite to each other. The light guide layer 10 and the shaping film 62 are arranged opposite to each other. Furthermore, the shaping film 62 is a film manufactured without cutting raw materials.

[0038] Multiple mold cavities 64 are provided inside the direction conversion layer 60. Each mold cavity 64 has a first inclined surface ISa and a second inclined surface ISb disposed in the Y direction on the opposite side to the first inclined surface ISa. Air is present, for example, inside the mold cavity 64. Multiple recesses 622 are provided on the main surface 621 of the shaping film 62. The open portions of each of the multiple recesses 622 are blocked by a substrate 30 disposed on the main surface 621 via a second adhesive layer 54, thereby forming the mold cavity 64. Alternatively, the mold cavity 64 may also be referred to as an internal space or an air mold cavity.

[0039] The lighting device 100 is used, for example, when the laminate 80 with the light guide layer is disposed on an adhered object such as glass, window, wall, floor, or ceiling. Light Lr emitted from the light source LS of the lighting device 100 enters the interior of the laminate 80 with the light guide layer from the end face 81 and is guided within the laminate 80. A portion of the light Lr guided within the laminate 80 with the light guide layer is reflected to the -Z side by either the first inclined surface ISa or the second inclined surface ISab of the mold cavity 64, and is emitted in the -Z direction, intersecting the main surface 621 of the forming film 62, through the exit surface 82 of the laminate 80 with the light guide layer that intersects the end face 81. The lighting device 100 can illuminate an interior space, etc., where the laminate 80 with the light guide layer is disposed, using the light Lr emitted substantially entirely from the exit surface 82 of the laminate 80 with the light guide layer.

[0040] like Figure 3 As shown, the shaping film 62 of this embodiment is an optical shaping film having a main surface 621. A plurality of recesses 622 arranged in the forming direction X with a first period P1 and a plurality of protrusions 65 arranged in the forming direction X with a second period P2 are provided on the main surface 621. The maximum depth Dx1 of the recesses 622 is greater than the maximum height Hx1 of the protrusions 65. In the shaping film 62, if n is set to a positive integer, then either n-0.05≤P1 / P2≤n+0.05 or n-0.05≤P2 / P1≤n+0.05 is satisfied. Ideally, the protrusions 65 are preferably absent, but as described later, the irregularities are created through the forming process of the shaping film 62. Furthermore, n can be any value as long as it is a positive integer. Furthermore, the condition "if n is set as a positive integer, then either n - 0.05 ≤ P1 / P2 ≤ n + 0.05 or n - 0.05 ≤ P2 / P1 ≤ n + 0.05" is synonymous with the condition "the absolute value of the result obtained by subtracting the value of P1 / P2 without decimals from the value of P1 / P2 containing decimals is less than ±0.05, or the absolute value of the result obtained by subtracting the value of P2 / P1 without decimals from the value of P2 / P1 containing decimals is less than ±0.05".

[0041] The first period P1 corresponds to the center-to-center distance of adjacent recesses 622 in the formation direction X. Figure 3 In the example shown, the center-to-center distance is the distance in the formation direction X between the centers C11 and C12 of adjacent recesses 622. In another viewpoint, the first period P1 can be the distance between the lowest points of adjacent recesses 622 in the formation direction X.

[0042] The second period P2 corresponds to the center-to-center distance between adjacent protrusions 65 in the formation direction X. Figure 3In the example shown, the center-to-center distance is the distance in the formation direction X between the centers C21 and C22 of adjacent protrusions 65. In another viewpoint, the second period P2 could be the distance between the highest points of adjacent protrusions 65 in the formation direction X. Figure 3 In the example shown, the first period P1 is approximately twice the second period P2, so P1 / P2 is approximately 2.0.

[0043] In the case of a shaped film having either a plurality of recesses or a first protrusion, when the shaped film is applied to a lighting device or the like, uneven brightness sometimes occurs in the light extracted from the lighting device via the shaped film. The cause of this uneven brightness will be explained below along with an example of the manufacturing method of the shaped film.

[0044] A shaped film with multiple recesses is manufactured by molding resin material using a mold. In this method of manufacturing the shaped film, firstly, a roller component made of metal or the like is prepared and becomes the raw material for the mold.

[0045] Next, the outer peripheral surface of the roller component is mirror-finished by cutting or grinding, thereby forming a roller-shaped mold for shaping the base into multiple recesses on the outer peripheral surface.

[0046] Next, multiple recesses are formed on the outer peripheral surface of the roller-shaped mold using machining methods such as cutting or grinding. During the machining of these recesses, a different machining tool than used for mirror finishing is employed, driven by an FTS (Fast Tool Servo) to continuously or intermittently cut or grind the outer peripheral surface of the mirror-finished roller-shaped mold. This process creates multiple recesses on the outer peripheral surface of the mold.

[0047] Next, a sheet-shaped resin substrate for an intermediate transfer part, made of resin material or the like, is wound around a portion of a roller-shaped mold. An active energy ray-curable resin is placed between the resin substrate and the roller-shaped mold, and the active energy ray-curable resin is cured by irradiation with active energy rays. By curing the active energy ray-curable resin, an intermediate transfer part composed of the resin substrate and the active energy ray-curable resin is obtained. A flipped shape, one of a plurality of recesses or protrusions in the mold, is formed on the surface of the intermediate transfer part. If the mold has recesses, the flipped shape formed on the intermediate transfer part becomes a protrusion. Conversely, if the mold has protrusions, the flipped shape formed on the intermediate transfer part becomes a recess.

[0048] Next, the sheet-like intermediate transfer component with a flipped shape is arranged on the outer peripheral surface of the roller component in such a way that it is wound around the roller component outside the roller-shaped mold, thus forming a transfer roller.

[0049] Next, a sheet-like resin substrate for shaping film, made of resin materials or the like, is wound onto a portion of a transfer roller. An active energy-curable resin with release properties is placed between the transfer roller and the resin substrate. The active energy-curable resin is then irradiated with active energy rays to cure. Through curing with the active energy-curable resin, a shaping film composed of the resin substrate and the active energy-curable resin is obtained. The shaping film is then peeled off from the transfer roller.

[0050] Through the above processes, the shape of any one of the multiple recesses or protrusions formed on the shaping film by the transfer roller is flipped. In other words, any one of the multiple recesses or protrusions formed on the roller-shaped mold is transferred to the shaping film via an intermediate transfer component.

[0051] Here, when the outer peripheral surface of the roller-shaped mold is mirror-finished, such as Figure 4 and Figure 5 As shown, sometimes either the concave or convex portion corresponding to the performance of the processing device may remain as processing marks or the like. Figure 4 This describes a situation where a mirror finish is performed on the outer peripheral surface 310 of a roller-shaped mold 300 that rotates around a rotation axis parallel to the X-axis, while the machining tool 200 is fed in the +X direction with a predetermined feed rate. Additionally, Figure 4 The magnified view shows the area around the outer periphery 310 of mold 300.

[0052] The front end 200a of the machining tool 200, which contacts the mold 300, has its shape determined by considering the characteristics (material) of the mold being machined, the height of the target's concavity and convexity, and the machinability during machining. It is generally an arc. Therefore, on the outer peripheral surface 310 of the mirror-finished roller-shaped mold 300, arranged in the forming direction X with a second cycle P2 corresponding to the feed amount of the machining tool 200, one of a plurality of concave or convex portions corresponding to the shape of the front end 200a of the machining tool 200 remains. Figure 4 In the example shown, multiple mold protrusions 302 corresponding to the shape of the front end 200a of the machining tool 200 remain on the outer peripheral surface 310 of the mold 300. In addition, even though the front end 200a of the machining tool 200 is made sharp, it is microscopically a shape with some degree of rounding.

[0053] on the other hand, Figure 5 This refers to the case where a roller-shaped mold 300 rotating around a rotation axis parallel to the X-axis has multiple mold recesses 301 machined on its outer peripheral surface 310, corresponding to multiple recesses on the forming film. Additionally, Figure 5The magnified view shows the vicinity of the outer peripheral surface 310 of the mold 300. On the outer peripheral surface 310 of the roller-shaped mold 300, a plurality of mold recesses 301 are formed in the forming direction X, overlapping with a plurality of mold protrusions 302 at a period approximately the same as the first period P1 of a plurality of recesses provided on the forming film.

[0054] A shaped film is manufactured by overlapping a mold 300 formed by multiple mold recesses 301 and multiple mold protrusions 302. The shapes corresponding to the multiple mold recesses 301 and multiple mold protrusions 302 are overlapped with the shaped film. However, for example, when the relative position of the mold recesses 301 with respect to the mold protrusions 302 changes depending on their position within the main surface of the shaped film, the reflective area of ​​the mold protrusions 302 also changes depending on their relative position. Due to this change in reflective area, the brightness of the light extracted from the main surface of the shaped film varies depending on its position within the main surface, sometimes resulting in uneven brightness of the light extracted from the main surface of the shaped film. Such uneven brightness degrades the quality of the lighting device equipped with the shaped film.

[0055] In the shaping film 62 of this embodiment, when n is set to a positive integer, the first period P1 becomes an approximately integer multiple of the second period P2 by satisfying either n - 0.05 ≤ P1 / P2 ≤ n + 0.05 or n - 0.05 ≤ P2 / P1 ≤ n + 0.05. Therefore, the relative position of the concave portion 622 to the convex portion 65 is approximately constant regardless of its position within the main surface 621 of the shaping film 62. The reflective area of ​​the convex portion 65 is also approximately constant regardless of its position within the main surface 621 of the shaping film 62. Because the reflective area of ​​the convex portion 65 is approximately constant, the brightness of the light extracted from the shaping film 62 is approximately constant regardless of its position within the main surface 621 of the shaping film 62. By making the brightness of the light extracted from the main surface 621 of the shaping film 62 approximately constant, brightness unevenness can be reduced in this embodiment.

[0056] exist Figure 1 In the example shown, a plurality of recesses 622 are further arranged on the main surface 621 of the shaping film 62 in the Y direction, which intersects the forming direction X. As a result, the unevenness of light brightness extracted from the main surface 621 of the shaping film 62, which extends in a two-dimensional direction, can also be reduced.

[0057] like Figure 2 As shown, the laminate 70 includes a shaping film 62 and a substrate 30 disposed opposite to the main surface 621 of the shaping film 62. This reduces the brightness unevenness of light extracted from the laminate 70 via the shaping film 62.

[0058] The laminate 80 with a light guide layer includes a laminate 70 and a light guide layer 10 disposed opposite to the shaping film 62. This reduces the brightness unevenness of light extracted from the laminate 80 with the light guide layer via the shaping film 62. Furthermore, the light guide layer 10 may also be disposed opposite to the substrate 30.

[0059] The lighting device 100 has a laminate 80 with a light guide layer and a light source LS disposed near the end face 81 of the laminate 80 with the light guide layer. As a result, the brightness unevenness of the light extracted from the lighting device 100 via the shaping film 62 can be reduced.

[0060] In the lighting device 100, light Lr emitted from the light source LS enters the interior of the light-guided laminate 80 from both the end face 81 and the end face 81 of the laminate 80 with the light guide layer. After being guided inside the laminate 80 with the light guide layer, it exits from the laminate 80 with the light guide layer through the exit surface 82. Thus, a surface lighting device 100 can be provided that can illuminate the light Lr extracted substantially entirely from the exit surface 82. Furthermore, the light source LS can be disposed on at least one of the end face 81 and the exit surface 82.

[0061] In addition, in this embodiment, such as Figure 5 As shown, the mold 300 has an outer peripheral surface 310 provided with a plurality of mold recesses 301 arranged in the forming direction X with a first period P1 and a plurality of mold protrusions 302 arranged in the forming direction X with a second period P2. The maximum depth Dx2 of the mold recesses 301 is greater than the maximum height Hx2 of the mold protrusions 302. If n is set as a positive integer, then either n-0.05≤P1 / P2≤n+0.05 or n-0.05≤P2 / P1≤n+0.05 is satisfied. Thus, in the shaped film 62 manufactured by the mold 300, the relative position of the recesses 622 corresponding to the mold recesses 301 relative to the protrusions 65 corresponding to the mold protrusions 302 is approximately constant regardless of their position within the main surface 621 of the shaped film 62. As a result, in this embodiment, a shaped film 62 that can reduce brightness unevenness can be provided. In addition, in this embodiment, a mold 300 for manufacturing a shaped film 62 that can reduce brightness unevenness can be provided. Furthermore, a mold 300 that meets the above conditions can be manufactured by controlling an FTS processing device or the like that processes the mold 300.

[0062] <Detailed Structure of Lighting Device 100>

[0063] The structure of the lighting device 100 will now be described in detail. The lighting device 100 has a light distribution control structure having multiple cavities 64. Each of the multiple cavities 64 has a first inclined surface ISa that directs a portion of the light Lr guided within the laminate 80 with the light guide layer toward the exit surface 82 via total internal reflection (TIR). Furthermore, the light Lr can be refracted according to the refractive index of the material constituting the interface when passing through the interface.

[0064] The laminate 80 with the light guide layer is configured to emit light Lr with a desired light distribution from the emission surface 82 via a light distribution control structure. The light distribution can be controlled, for example, by adjusting the cross-sectional shape, planar shape, size, arrangement density, and distribution of the mold cavity 64.

[0065] The laminate 80 with the light guide layer has a visible light transmittance of 60% or more and a haze value of less than 30%. The visible light transmittance is preferably 70% or more, more preferably 80% or more. The haze value is preferably less than 10%, more preferably 5% or less. The laminate 80 with the light guide layer has high visible light transmittance and low haze value, thus allowing objects to be seen (displayed) through it. Visible light is light with a wavelength of 380 nm or more and 780 nm or less. Visible light transmittance and haze value can be measured using a haze meter (Murakami Color Technology Research Institute: trade name HM-150), etc.

[0066] When the light guide layer 10 is viewed from the normal direction of the emission surface 82, the ratio of the area of ​​the plurality of cavities 64 to the area of ​​the light guide layer 10 (occupancy rate) is preferably 1% or more and 80% or less. The upper limit of the above-mentioned occupancy rate is more preferably 50% or less, more preferably 45% or less, and more preferably 30% or less, more preferably 10% or less, and more preferably 5% or less, in order to obtain at least one of high transmittance and low haze value.

[0067] For example, a haze value of 30% can be obtained when the area ratio of the mold cavity 64 is 50%. Furthermore, the area ratio of the mold cavity 64 can be uniform, or it can increase with the distance from the light source LS, ensuring that the brightness does not decrease even with increased distance from the light source LS. For mass production using roll-to-roll or roll-to-sheet methods, a uniform area ratio of the mold cavity 64 is preferred.

[0068] In the laminate 80 with the light guide layer, the light guide layer 10 and the shaping film 62 are bonded together by a first adhesive layer 52. Additionally, the substrate 30 is bonded to the shaping film 62 by the shaping film 62 and a second adhesive layer 54 constituting the direction conversion layer 60. The light guide layer 10 and the substrate 30 can be transparent substrates or films.

[0069] exist Figure 1 In the example shown, multiple cavities 64 are discretely arranged in the X and Y directions of the light guide layer 10. However, the discrete arrangement of the cavities 64 can be appropriately set according to the shape of the light guide layer 10 or the required light distribution.

[0070] exist Figure 1 In the example shown, multiple mold cavities 64, having substantially the same shape and convex in the same direction, are discretely and periodically arranged throughout the region in the X and Y directions. In this case, the first period P1 is preferably 10 μm or more and 500 μm or less, and the spacing Py is preferably 10 μm or more and 500 μm or less. Figure 1 In the example shown, the laminate 80 with the light guide layer also has a cavity 64 that is offset by 1 / 2 of the first period P1 in the X direction and offset by 1 / 2 of the spacing Py in the Y direction.

[0071] A light source LS is, for example, an LED (Light Emitting Diode) device. Multiple LED devices are arranged in the X direction. There are no particular restrictions on the number and arrangement of LEDs. Furthermore, a light source LS is not limited to LED devices; it can also be a halogen lamp, etc.

[0072] Reference Figures 6-8 The detailed structure of mold cavity 64 is described below. Figure 6 This is a schematic cross-sectional view showing an example of mold cavity 64. Figure 7 This is a schematic top view representing the first example of mold cavity 64. Figure 8 This is a schematic top view representing a second example of mold cavity 64.

[0073] Figure 6 The cross-sectional shape of the mold cavity 64 shown is approximately triangular. However, the cross-sectional shape of the mold cavity 64 is not limited to approximately triangular; it can also be approximately trapezoidal, etc. Figure 6 In the example shown, the tilt angle θa of the first inclined surface ISa is larger than the tilt angle θb of the second inclined surface ISb.

[0074] The tilt angle θa of the first tilted surface ISa on the light source LS side is, for example, 10° or more and 70° or less. If the tilt angle θa is less than 10°, the controllability of light distribution decreases, and the light extraction efficiency also decreases. On the other hand, when the tilt angle θa exceeds 70°, the processing of the shaping film 62 sometimes becomes difficult. By setting the tilt angle θa to 10° or more and 70° or less, the light extraction efficiency can be improved, and the processing of the shaping film 62 can be made easier.

[0075] The tilt angle θb of the second tilted surface ISb is, for example, 50° or more and 100° or less. If the tilt angle θb is less than 50°, stray light may sometimes be generated in an undesirable direction. On the other hand, if the tilt angle θb exceeds 100°, the processing of the shaping film 62 may become difficult. By setting the tilt angle θb to 50° or more and 100° or less, the light extraction efficiency can be improved, and the processing of the shaping film 62 can be made easier.

[0076] Figure 7 The first inclined surface ISa shown is a curved surface that bulges towards the light source LS when viewed from above. Here, the light emitted from the multiple LED devices constituting the light source LS has a spread relative to the Y direction. Therefore, when the first inclined surface ISa has a curved surface bulging towards the light source LS, the first inclined surface ISa acts on the light uniformly. Furthermore, when a coupling optical system is provided between the light source LS and the end face 81 of the laminate 80 with the light guide layer, and light with high parallelism (light with small spread relative to the Y direction) is incident, the first inclined surface ISa can also be parallel to the X direction.

[0077] like Figure 7 and Figure 8 As shown, the length L of the mold cavity 64 is preferably 10 μm or more and 500 μm or less, and the width W is preferably 1 μm or more and 100 μm or less. The length L is preferably, for example, more than twice the width W. The height H is preferably 1 μm or more and 100 μm or less. Furthermore, depending on the formation including the top view, it has... Figure 7 The machining accuracy of the shaped film 62 when forming the recess 622 of the shape shown sometimes results in a shape that, when viewed from above, has... Figure 8 The recess 622 is shown in the figure. Even in this case, the shape of the mold cavity 64 when viewed from above can be determined by the length L and the width W.

[0078] The shaped film 62 can be manufactured, for example, using polymethyl methacrylate (PMMA). The total thickness of the shaped film 62 is, for example, 200 μm or less, 150 μm or less, with a lower limit of 20 μm or more. The visible light transmittance of the shaped film 62 is 60% or more, and the haze value is less than 30%. The visible light transmittance is preferably 70% or more, more preferably 80% or more. The haze value is preferably less than 10%, more preferably 5% or less. Visible light can be measured using the methods described above.

[0079] The light guide layer 10 is formed of a known material with high transmittance of visible light. For example, it is formed of acrylic resins such as polymethyl methacrylate (PMMA), polycarbonate (PC) resins, cycloolefin resins, or glass (quartz glass, alkali-free glass, borosilicate glass, etc.). The refractive index nGP of the light guide layer 10 is, for example, 1.40 or higher and 1.80 or lower. It should be noted that, unless otherwise specified, the refractive index refers to the refractive index measured using an ellipsometer at a wavelength of 550 nm. The thickness of the light guide layer 10 can be appropriately set according to the application. For example, the thickness of the light guide layer 10 is 0.05 mm or higher and 50 mm or lower.

[0080] The thickness of the substrate 30 is, for example, 1 μm or more and 1000 μm or less, preferably 10 μm or more and 100 μm or less, and more preferably 20 μm or more and 80 μm or less. The refractive index of the substrate 30 is preferably 1.40 or more and 1.70 or less, and more preferably 1.43 or more and 1.65 or less.

[0081] The thicknesses of the first adhesive layer 52 and the second adhesive layer 54 are each independently, for example, 0.1 μm or more and 100 μm or less, preferably 0.3 μm or more and 100 μm or less, and more preferably 0.5 μm or more and 50 μm or less. The refractive indices of the first adhesive layer 52 and the second adhesive layer 54 are each independently preferably 1.42 or more and 1.60 or less, more preferably 1.47 or more and 1.58 or less. Furthermore, the refractive indices of the first adhesive layer 52 and the second adhesive layer 54 are preferably close to the refractive index of the light guide layer 10 or the shaping film 62 to which they are attached, and the absolute value of the difference in refractive indices is preferably 0.2 or less.

[0082] The second adhesive layer 54 is preferably bonded without filling the recesses 622 of the shaped film 62. As an adhesive suitable for forming the second adhesive layer 54, adhesives described in the applicant's international applications PCT / JP2021 / 006452 and PCT / JP2021 / 006453, or Japanese Patent Application No. 2021-025496, are preferred. The disclosures of these applications are incorporated herein by reference in their entirety. Polyester-based adhesives described in Japanese Patent Application No. 2021-025496 are particularly preferred.

[0083] <Evaluation results of uneven brightness>

[0084] Next, refer to Figures 9-11 The evaluation results of the brightness unevenness in the shaped film 62 are explained. Figure 9 This is a figure representing an example of the evaluation results for the brightness unevenness of the shaped film 62. Figure 9 and Figure 1 Similarly, the recess 622 of the shaped film 62 has a length direction. Figure 9The orientation of the length direction of the recess 622 is the same as that of the recess 622. Figure 1 Different examples. In Figure 1 In the middle, the length direction of the recess 622 is consistent with the forming direction. Figure 9 In the top view, the direction orthogonal to the length direction of the recess 622 is consistent with the formation direction. Figure 10 This is a diagram illustrating an example of the brightness distribution of light extracted from the main surface 621 of the shaped film 62 in Example 1. Figure 11 This is a diagram illustrating an example of the brightness distribution of light extracted from the main surface of the shaped film in Example 3.

[0085] exist Figure 9 In this example, Examples 1 and 2 are implementation examples, and Example 3 is a comparative example. Figure 9 The “schematic diagram” is a schematic three-dimensional view of a portion of the shaped film used to represent the positional relationship between the concave and convex portions in the shaped film. Figure 9 In the method for evaluating brightness unevenness shown, firstly, a substrate 30 (PMMA: 40μm) is bonded to the main surface 621 of the shaped film 62 via a second adhesive layer 54 (polyester adhesive). Then, the side of the shaped film 62 opposite to the main surface 621 is bonded to a light-transmitting substrate 401. The light-transmitting substrate 401 is ACRYLITE EX manufactured by Mitsubishi Chemical Corporation, with dimensions of 145mm in length, 1000mm in width, and 5mm in thickness. The adhesive used is CS 9862 manufactured by Nitto Denko Corporation. After bonding the shaped film 62 to the light-transmitting substrate 401, an evaluation sample 400 is prepared by autoclaving at a temperature of 50 degrees Celsius, a pressure of 0.5 MPa, and a time of 15 minutes.

[0086] The shaped membrane 62 uses a membrane with the specifications shown below.

[0087] Thickness: 130μm

[0088] • Directions orthogonal to the first period ( Figure 9 Spacing in the Y direction: 140μm

[0089] • The tilt angle θa of the first inclined plane ISa is 49°

[0090] • The area percentage of the multiple recesses 622 in the shaped film 62: 3.7%

[0091] ·Shape of recess 622: Figure 8 The shape shown is 20 μm wide and 80 μm long.

[0092] • First period P1: as shown in Table 1 below.

[0093] • Second period P2: as shown in Table 1 below.

[0094] Figure 10The image shown is a partial image of the illumination device 100 equipped with the shaped film of Example 1, taken from the normal direction of the exit surface. Figure 11 The image shown is obtained by taking a portion of the emitting surface of the illumination device equipped with the shaped film of Example 2 from the normal direction of the emitting surface. In the evaluation of brightness unevenness, the presence or absence of brightness unevenness is determined by visually observing the image taken from the normal direction of the emitting surface.

[0095] exist Figure 9 Example 1 illustrates the case where recesses 622 are positioned only at locations overlapping with protrusions 65. In Example 1, as shown in the schematic diagram, multiple recesses 622 are located only near the vertices of protrusions 65, not between adjacent protrusions 65. In Example 1, if n is set to a positive integer, then either n - 0.05 ≤ P1 / P2 ≤ n + 0.05 or n - 0.05 ≤ P2 / P1 ≤ n + 0.05 is satisfied.

[0096] Example 2 illustrates the case where recesses 622 are arranged only between adjacent protrusions 65. In Example 2, as shown in the "Schematic Diagram," the multiple recesses 622 are located only between adjacent protrusions 65, not near the vertices of the protrusions 65. In Example 2, if n is set as a positive integer, then either n - 0.05 ≤ P1 / P2 ≤ n + 0.05 or n - 0.05 ≤ P2 / P1 ≤ n + 0.05 is satisfied.

[0097] Example 3 illustrates a case where recesses 622 are mixed and arranged at positions overlapping with convex portions 65 and between adjacent convex portions 65. In Example 3, as shown in the schematic diagram, some of the recesses 622 are located near the vertices of the convex portions 65, while others are located between adjacent convex portions 65. In Example 3, if n is set to a positive integer, neither the conditions n - 0.05 ≤ P1 / P2 ≤ n + 0.05 nor n - 0.05 ≤ P2 / P1 ≤ n + 0.05 are satisfied.

[0098] like Figure 10 As shown, no uneven brightness was observed in Example 1. The same is true in Example 2. Therefore, the "uneven brightness" in both Example 1 and Example 2 is "none", and the "judgment" is "○".

[0099] On the other hand, such as Figure 11 As shown, in Example 3, a stripe-like brightness unevenness S extending along the Y direction is visually recognized. Figure 11 In the image shown, bright stripes (white areas) extending along the Y direction and dark stripes (black areas) extending along the Y direction are generated. Therefore, in Example 3, "uneven brightness" is "present" and "judgment" is "×".

[0100] Table 1 below shows Figure 9The evaluation results for Examples 1-3, Comparative Example 1, and Comparative Example 2, excluding Examples 1-3, are shown. In Examples 1 and 2, P1 / P2 = 2.00, satisfying the condition P1 / P2 ≤ n + 0.05 when n = 2. In Example 3, P1 / P2 = 3.00, satisfying the condition P1 / P2 ≤ n + 0.05 when n = 3. In Comparative Example 1, P1 / P2 = 2.06. If n is set to a positive integer, neither the conditions n - 0.05 ≤ P1 / P2 ≤ n + 0.05 nor n - 0.05 ≤ P2 / P1 ≤ n + 0.05 are satisfied. In Comparative Example 2, P1 / P2 = 1.50. If n is set as a positive integer, then neither of the following conditions is satisfied: n - 0.05 ≤ P1 / P2 ≤ n + 0.05, nor n - 0.05 ≤ P2 / P1 ≤ n + 0.05.

[0101] [Table 1]

[0102]

[0103] As shown in Table 1, in Examples 1 to 3, the "determination" is "○", and in Comparative Examples 1 and 2, the "determination" is "×".

[0104] As can be seen from the above, in the shaping film 62 of Examples 1, 2, and Examples 1 to 3, the "determination" is "○", which can reduce uneven brightness.

[0105] [Other preferred variations]

[0106] Figure 12 This is a schematic cross-sectional view showing a second example of the shaped film 62 of the embodiment. Figure 12 Indicates and Figure 1 The cross-section of the second example of the shaped film 62 corresponds to line III-III in the diagram. This will be shown later. Figure 13 and Figure 14 The same applies in China. Figure 12 In the second example of the shaped film 62 shown, the plurality of recesses 622 are disposed only near the apexes of the plurality of protrusions 65. P1 / P2 is approximately 3.00.

[0107] Figure 13 This is a schematic cross-sectional view showing a third example of the shaped film 62 according to the embodiment. Figure 13 In the third example of the shaped film 62 shown, the plurality of recesses 622 are respectively disposed only between adjacent protrusions 65 in the plurality of protrusions 65. P1 / P2 is approximately 3.00.

[0108] Figure 14 This is a schematic cross-sectional view showing a fourth example of the shaped film 62 according to the embodiment. Figure 14In the fourth example of the shaped film 62 shown, the plurality of recesses 622 are disposed only near the apexes of the plurality of protrusions 65. P1 / P2 is approximately 4.00.

[0109] exist Figure 12 The second example shown Figure 13 The third example shown and Figure 14 In the fourth example shown, the same effect as the implementation method can be obtained.

[0110] Figure 15 This is a schematic cross-sectional view showing a second example of an illumination device 100 equipped with a shaped film according to the embodiment. Figure 15 The second example of the lighting device 100 is related to... Figure 1 A portion of the cross section corresponding to line II-II.

[0111] exist Figure 15 In the second example of the lighting device 100 shown, the light guide layer 10 is disposed opposite to the substrate 30. Light incident from the light source LS into the laminate 80 with the light guide layer exits from the exit surface 82 located on the side opposite to the light guide layer 10. In the second example of the lighting device 100, these aspects are mainly related to... Figure 2 The first example of the lighting device 100 shown is different.

[0112] exist Figure 15 In the second example of the lighting device 100 shown, the same effect as in the embodiment can also be obtained. It should be noted that the exit surface from which light is emitted from the laminate 80 with the light guide layer can be at least one of the upper surface (the +Z side surface) and the lower surface (the -Z side surface) of the laminate 80 with the light guide layer.

[0113] The laminate 80 with the light guide layer may have a low-refractive-index layer disposed on one side of the laminate 80 with the light guide layer and having a lower refractive index than the light guide layer 10 or the shaping film 62. Additionally, the laminate 80 with the light guide layer may have a low-refractive-index layer between the shaping film 62 and the substrate 30. The refractive index of the low-refractive-index layer is preferably 1.30 or less. Furthermore, the laminate 80 with the light guide layer may have a hard coating layer and an anti-reflective layer.

[0114] The substrate for the laminate 80 with the light-guiding layer is not limited to glass, but can also be a non-transparent component such as an electronic substrate like a liquid crystal cell, a ceiling, a wall, or a floor. The shaping film 62 can extract light not only from the side opposite to the substrate, but also from the side where the substrate is located. In this case, if the substrate has high light transmittance, the extracted light can pass through it; if the substrate has low light transmittance, it can reflect the light.

[0115] The preferred embodiments have been described in detail above, but are not limited to the embodiments described above. Various modifications and substitutions can be made to the embodiments described above without departing from the scope of the claims.

[0116] The ordinal numbers, quantities, and other numerical values ​​used in the description of the embodiments are all illustrative for the purpose of specifically illustrating the technology of the present invention, and the present invention is not limited to the illustrative numbers. Furthermore, the connection relationships between the constituent elements are illustrative for the purpose of specifically illustrating the technology of the present invention, and are not intended to limit the connection relationships for achieving the functions of the present invention.

[0117] The shaped film, laminate, and light-guiding layer of the embodiments can reduce brightness unevenness. Therefore, by combining them with a light source and configuring them on building components such as glass, windows, walls, floors, and ceilings, they can reduce brightness unevenness and brightly illuminate the interior or exterior spaces of buildings. The same applies to the lighting devices of the embodiments.

[0118] Furthermore, in the lighting device of the embodiment, by using the lighting device as a partition, it is possible to appropriately partition the room or block out desired spaces. Moreover, by disposing the shaped film, the laminate, and the laminate with the light guide layer of the embodiment onto the glass substrate of display devices such as liquid crystal panels and organic EL (Electro Luminescence) display panels, it is possible to brighten the backlighting and other components in the display device. In addition, the shaped film, the laminate, the laminate with the light guide layer, and the lighting device of the embodiment can provide new applications besides those described above.

[0119] This application claims priority to Japanese Patent Application No. 2024-055496, filed with the Japan Patent Office on March 29, 2024, and includes the entire contents of that Japanese patent application.

[0120] Explanation of reference numerals in the attached figures

[0121] 10: Light guide layer

[0122] 30: Substrate

[0123] 52: First adhesive layer

[0124] 54: Second adhesive layer

[0125] 60: Direction Conversion Layer

[0126] 62: Shaped membrane

[0127] 621: Main side

[0128] 622: concave part

[0129] 64: Mold cavity

[0130] 65: convex part

[0131] 70: Layered body

[0132] 80: Laminated body with light guide layer

[0133] 81: End face

[0134] 82: Exit surface

[0135] 100: Lighting device

[0136] 200: Machining tools

[0137] 300: Mold

[0138] 301: Mold concave part

[0139] 302: Mold convex part

[0140] 310: Outer peripheral surface

[0141] C11, C12, C21, C22: Center

[0142] Dx1: Maximum depth of the recess

[0143] Dx2: Maximum depth of the mold recess

[0144] H: Height

[0145] Hx1: Maximum depth of convex part

[0146] Hx2: Maximum depth of the mold protrusion

[0147] ISa: First Inclined Surface

[0148] ISb: Second inclined surface

[0149] L: Length

[0150] Lr: light

[0151] LS: Light source

[0152] P1: First Cycle

[0153] P2: Second cycle

[0154] Py: Spacing

[0155] S: Uneven brightness

[0156] W: Width

[0157] θa, θb: Inclination angle

Claims

1. A shaping film, which is an optical shaping film having a main surface, characterized in that, The main surface is provided with a plurality of recesses arranged in the forming direction with a first period P1 and a plurality of protrusions arranged in the forming direction with a second period P2. The maximum depth of the concave portion is greater than the maximum height of the convex portion. When n is set as a positive integer, either n - 0.05 ≤ P1 / P2 ≤ n + 0.05 or n - 0.05 ≤ P2 / P1 ≤ n + 0.05 is satisfied.

2. The shaping film according to claim 1, characterized in that, On the main surface, the plurality of recesses are further arranged in a direction intersecting the forming direction.

3. A laminated body, characterized in that, Include: The shaped film according to claim 1 or 2; A substrate disposed opposite to the main surface of the shaped film.

4. A laminate with a light-guiding layer, characterized in that, Include: The laminate as described in claim 3; A light guide layer disposed opposite to either the shaped film or the substrate.

5. A lighting device, characterized in that, have: The laminate with a light guide layer as described in claim 4; A light source disposed near the end face of the laminate with the light guide layer.

6. The lighting device according to claim 5, characterized in that, Light emitted from the light source enters the interior of the light-guided stack from at least one of the end face and the exit surface of the light-guided stack that intersects the end face of the light-guided stack. After being guided inside the light-guided stack, it exits through the exit surface.

7. A mold, characterized in that, It has an outer peripheral surface, which is provided with a plurality of mold recesses arranged in a first period (P1) along the forming direction and a plurality of mold protrusions arranged in a second period (P2) along the forming direction. The maximum depth of the mold recess is greater than the maximum height of the mold protrusion. When n is set as a positive integer, either n - 0.05 ≤ P1 / P2 ≤ n + 0.05 or n - 0.05 ≤ P2 / P1 ≤ n + 0.05 is satisfied.

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