Reflection polarization optical element, optical apparatus, display device, and method of manufacturing reflection polarization optical element

Abstract

To provide a reflection polarization optical element in which the occurrence of floating of a film in a peripheral part is reduced.SOLUTION: The reflection polarization optical element includes a substrate including a curved surface portion having a first diameter in a plan view as viewed in an optical axis direction and a second diameter longer than the first diameter in the plan view, a surface of the curved surface portion constituting a curved surface, and a reflection polarizing film including a transmission axis and a reflection axis and bonded to a curved surface of the curved surface portion, the reflection polarizing film being disposed such that an extending direction of the reflection axis and an extending direction of the first diameter are parallel to each other in the plan view.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a reflective polarizing optical element, an optical instrument, a display device, and a method for manufacturing a reflective polarizing optical element. [Background technology]

[0002] In recent years, head-mounted displays have been used in various fields, such as virtual reality (VR), augmented reality (AR), and mixed reality (MR). Head-mounted displays have an optical system that focuses images displayed on the display at the user's eye position. By folding the optical path using circularly polarized light and a half mirror, head-mounted displays achieve compact, lightweight, and high-quality optical systems. Furthermore, head-mounted displays require a nose guard when worn by the user and require space for installing electronic devices such as motors and sensors. For this reason, the optical elements used in head-mounted displays are often elliptical or non-axisymmetric, with at least one side cut off and a major axis and a minor axis, rather than the axis-symmetric circular shapes used in digital cameras.

[0003] Furthermore, in order to reduce the size and weight of head-mounted displays, elements are also used in which a film having desired optical properties is attached to a curved substrate. Examples of such films include polarizing films, reflective polarizing films (polarizing beam splitter (PBS) films), and retardation films. Patent Document 1, for example, discloses an optical element to which a reflective polarizing film is attached as an example of such an optical element. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2022-091938 Summary of the Invention [Problem to be solved by the invention]

[0005] However, it is becoming increasingly recognized that in the reflective polarizing optical element disclosed in Patent Document 1, poor adhesion areas of the film (so-called "floats") may occur in the periphery of the reflective polarizing optical element during durability tests in high-temperature environments. Such floats may be the starting point for peeling of the film.

[0006] The present invention has been made in consideration of the above circumstances, and one of its objects is to provide a reflective polarizing optical element that reduces the occurrence of film lift in the peripheral areas, and a method for manufacturing such a reflective polarizing optical element. [Means for solving the problem]

[0007] In order to solve the above problems, a reflective polarization optical element according to one aspect of the present invention comprises: a substrate having a curved surface portion that has a first diameter in a plan view seen in the optical axis direction and a second diameter in the plan view that is longer than the first diameter, and whose surface forms a curved surface; a reflective polarizing film having a transmission axis and a reflection axis, attached to the curved surface of the curved surface portion, wherein the extension direction of the reflection axis and the extension direction of the first diameter are arranged parallel to each other in the plan view; Equipped with. [Effects of the Invention]

[0008] According to one aspect of the present invention, a reflective polarizing optical element can be provided in which the occurrence of lifting of the film in the peripheral portion is reduced. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a schematic diagram illustrating an example of a reflective polarizing optical element according to an embodiment of the present invention. [Figure 2] 10A and 10B are diagrams illustrating examples of substrate shapes of a reflective polarization optical element according to another embodiment of the present invention. [Figure 3] 5A to 5C are diagrams illustrating an example of a method for manufacturing a reflective polarization optical element according to an embodiment of the present invention. [Figure 4] 1A to 1C are diagrams illustrating an example of a manufacturing method according to Example 1. [Figure 5] 10A to 10C are diagrams illustrating an example of a manufacturing method according to Example 4. [Figure 6] FIG. 10 is a schematic diagram illustrating an example of a reflective polarization optical element according to Example 6. [Figure 7] FIG. 10 is a schematic diagram illustrating an example of a reflective polarization optical element according to Example 7. [Figure 8-1] 10 is a diagram illustrating an example of a substrate shape and a reflective polarizing film used in Example 8. FIG. [Figure 8-2] 10A and 10B are diagrams illustrating an example of a manufacturing method according to Example 8. [Figure 8-3] 10A and 10B are diagrams illustrating an example of a manufacturing method according to Example 8. [Figure 8-4] 10A and 10B are diagrams illustrating an example of a manufacturing method according to Example 8. [Figure 9] 1 is a schematic diagram showing an example of an optical device using a reflective polarization optical element according to the present invention. [Figure 10] 1 is a schematic diagram showing an example of a display device using a reflective polarizing optical element according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0010] Preferred embodiments and examples will be described in detail below with reference to the drawings. In the following description, common components across multiple drawings are designated by common reference numerals. Therefore, the common components will be described with mutual reference to multiple drawings, and descriptions of components designated by common reference numerals will be omitted as appropriate. Furthermore, the dimensions, materials, shapes, and relative positions of components illustrated in the following embodiments and examples are arbitrary and can be changed depending on the configuration of the device to which the present invention is applied or various conditions.

[0011] [First embodiment] A reflective polarizing optical element according to one embodiment of the present invention will be described below with reference to FIGS. 1 to 2(c). The reflective polarizing film used in this embodiment is composed of two layers, Sheet A and Sheet B, made of different materials. More specifically, for example, several hundred layers of these films made of different materials are alternately stacked, and the laminated film is stretched in a certain direction after stacking. Through the above operations, this laminated film has a reflective polarizing function. In such a reflective polarizing film, the birefringence generated in Sheet A and Sheet B by stretching is different. Therefore, with respect to light incident on the film, light incident parallel to the stretching direction (reflection axis) is reflected without being transmitted, and light incident perpendicular to the stretching direction (transmission axis) can be transmitted.

[0012] Due to the manufacturing process described above, such reflective polarizing films have the characteristic of being highly stretchable in the transmission axis direction but not in the reflection axis direction. When affixed to a substrate, the reflective polarizing film may be subjected to a tensile load throughout. Based on the aforementioned characteristics, it is anticipated that, particularly in the peripheral portion of the reflective polarizing optical element, the film will not be able to stretch sufficiently under the load, and will not be able to conform to the curved surface of the substrate, resulting in lifting of the film at or near the edge in the reflection axis direction. The present invention is based on the above assumption.

[0013] Fig. 1 is a schematic diagram showing an example of a reflective polarization optical element 10 according to this embodiment. In Fig. 1, the diagram on the left is a plan view showing the reflective polarization optical element 10 in a plan view seen in the direction in which light enters the reflective polarization optical element 10, and the diagram on the right is a cross-sectional view showing the cross section of the reflective polarization optical element 10 taken along a minor axis 11c, which will be described later.

[0014] 1, a reflective polarizing optical element 10 includes a substrate 11 and a reflective polarizing film 12 attached to the substrate 11. The substrate 11 illustrated here has a curved surface portion 11a located at the center and a peripheral portion 11b provided adjacent to the curved surface portion 11a on the periphery of the curved surface portion 11a. In the illustrated reflective polarizing optical element 10, the reflective polarizing film 12 is attached to the curved surface of the curved surface portion 11a.

[0015] The curved surface portion 11a has a non-axisymmetric shape in a plan view seen in the optical axis direction of the substrate 11, and has a minor axis 11c and a major axis 11d that is longer than the minor axis 11c. The optical axis direction of the substrate 11 coincides with the optical axis direction of the reflective polarization optical element 10, which is the direction in which light enters the reflective polarization optical element 10.

[0016] In this embodiment, the minor axis 11c is the shortest diameter among the diameters passing through a reference point on the shape of the substrate 11 in a planar view. The major axis 11d is the longest diameter among the diameters passing through a reference point on the shape of the substrate 11 in a planar view. Specifically, in a planar view seen in the optical axis direction of the substrate 11, the curved surface portion 11a has a partially circular shape surrounded by an arc formed by a portion of the circumference of a circle and a line connecting both ends of the arc. The line connecting both ends of the arc is, for example, a straight line, but may also be a curved line, a bent line, or the like. In this case, the minor axis 11c is the shortest diameter among the diameters passing through the center point O of the circle constituting the arc of the curved surface portion 11a in a planar view as a reference point. The major axis 11d is the longest diameter among the diameters passing through the center point O of the circle of the arc of the curved surface portion 11a in a planar view as a reference point. Therefore, depending on the arrangement of the missing portion of the arc, the minor axis 11c and the major axis 11d do not necessarily have to be perpendicular to each other.

[0017] The curved surface portion 11a of the substrate 11 can function as a lens. The curved surface of the curved surface portion 11a to which the reflective polarizing film 12 is attached has a convex or concave shape, and may be spherical or aspherical. The surface of the curved surface portion 11a opposite to the curved surface to which the reflective polarizing film 12 is attached may be flat, or may be a convex or concave curved surface, and if it is a curved surface, it may be spherical or aspherical.

[0018] The peripheral edge portion 11b is an optically ineffective region. For example, the peripheral edge portion 11b may be provided as a mold release margin when manufacturing the substrate 11, particularly when manufacturing the substrate 11 by injection molding, or may be provided for attachment to the housing of an optical device such as a head-mounted display. The peripheral edge portion 11b may be curved or flat, and may have an axisymmetric or non-axisymmetric shape. Furthermore, the peripheral edge portion 11b does not need to be provided along the entire circumference of the curved surface portion 11a, but may be provided along a portion of the entire circumference of the curved surface portion 11a. Furthermore, in some cases, the peripheral edge portion 11b may not be provided. Furthermore, the peripheral edge portion 11b may be formed by a flat surface.

[0019] A step portion 11e can be provided on at least the outermost periphery of the minor axis 11c of the curved surface portion 11a. When a peripheral edge portion 11b is provided, the step portion 11e is disposed between the curved surface portion 11a and the peripheral edge portion 11b, and serves to connect the curved surface portion 11a and the peripheral edge portion 11b.

[0020] The shape of the substrate 11 in a plan view in the optical axis direction of the substrate 11 is not limited to the shape shown in Fig. 1. Examples of the shape of the substrate 11 will be described below with reference to Figs. 2(a) to 2(c). Figs. 2(a) to 2(c) are plan views showing other examples of the shape of the substrate 11 in a plan view in the optical axis direction of the substrate 11.

[0021] 2(a), the curved surface portion 11a-2 has a partially cut circular shape surrounded by two arcs and two straight lines in a plan view. The two arcs are positioned opposite each other on the circumference of the same circle, and the two straight lines are provided as two opposing parallel sides connecting two sets of opposing ends of the two arcs. The illustrated substrate 11-2 has a peripheral edge portion 11b-2 that has a circular outer shape in a plan view.

[0022] In the example of substrate 11-2, the reference point is the center point O of a circle that forms two arcs in a plan view of substrate 11-2. Minor axis 11c corresponds to the distance between two straight line segments that pass through center point O, and major axis 11d corresponds to the distance between two arcs that pass through center point O and are perpendicular to minor axis 11c.

[0023] In the case of the substrate 11-3 illustrated in FIG. 2(b), the curved surface portion 11a-3 has a segmented circular shape surrounded by two arcs and two straight lines in a plan view. The two straight lines extend in different directions and do not face each other, forming two straight sides of the segmented circular shape. The two arcs are part of the circumference of the same circle and are arranged so as to connect the two adjacent pairs of ends of these two sides. In the case of the illustrated substrate 11-3, the substrate 11-3 has a peripheral edge portion 11b-3 of the same width provided on the outer periphery of the curved surface portion 11a-3 in a plan view.

[0024] 2(a) or 2(b), the curved surface portion has two straight lines in a plan view. However, the number of straight lines constituting the curved surface portion is not limited to two, and the curved surface portion may have three or more straight lines in a plan view of the substrate. In this case, the curved surface portion has three or more arcs in a plan view, each of which is part of the circumference of the same circle, and two adjacent ends of the straight lines are connected by an arc.

[0025] In the example of substrate 11-3, the reference point is also the center point O of the circle that constitutes two arcs in a plan view of substrate 11-3. However, unlike the example of FIG. 2(a), minor axis 11c is the shortest diameter among the diameters that pass through center point O, and is the distance between one straight line and one arc. Furthermore, major axis 11d is the longest diameter among the diameters that pass through center point O, and is the distance between two arcs. In this case, the extension directions of minor axis 11c and major axis 11d are not perpendicular to each other.

[0026] 2(c), the curved surface 11a-4 has a shape formed by a plurality of arcs with different curvatures, such as a spectacle lens, in a plan view. As shown in the example, the substrate 11-4 can be configured without a peripheral edge, unlike the substrates shown in FIGS. 1 to 2(b).

[0027] Furthermore, in the illustrated substrate 11-4, since no identical circle exists, it is not possible to determine the center point in a planar view of the substrate 11-4. In such a case, the centroid C of the curved surface portion 11a-4 in a planar view of the substrate 11-4 can be used as a reference point. The minor axis 11c-4 is the shortest diameter passing through the centroid C of the shape of the curved surface portion 11a in a planar view, and the major axis 11d-4 is the longest diameter passing through the centroid C.

[0028] Optical devices using the reflective polarizing optical element 10, particularly head-mounted displays, are expected to be worn on the user's face, particularly around the eyes and nose, which places restrictions on the size of the device. Therefore, in order to protect the user's nose and to ensure space for installing electronic devices such as motors and sensors, the shape of the substrate is often asymmetric rather than axially symmetric. In such cases, the substrate shape shown in FIG. 2(c) is expected, and for such substrates and curved surfaces, the minor axis and major axis can be defined by using the centroid C as the reference point, as described above.

[0029] The substrate material described above can be any transparent material, regardless of whether it is plastic or glass, that is transmissive to light such as visible light targeted by the reflective polarization optical element 10. When using plastic, it is preferable to use a material that can be formed by injection molding and is used for optical purposes. Specifically, the plastic material used for the substrate is preferably one with low birefringence. Examples include polycarbonate (PC), polyester (PEs), polymethyl methacrylate (PMMA), cycloolefin polymer (COP), and cycloolefin copolymer (COC). When using glass, the material is not particularly limited, but examples include synthetic quartz and the common glass material BK-7.

[0030] The reflective polarizing film 12 is attached to the curved surface of the curved portion of the substrate via an adhesive layer 13 (see Figure 3(b)). As described above, the reflective polarizing film 12 is not particularly limited, but is made by stacking several hundred layers of two films made of different materials, alternating them, and stretching the film in a certain direction. As shown in Figure 1, the reflective polarizing film 12 has a reflection axis 12a and a transmission axis 12b that is perpendicular to the reflection axis 12a, and is able to reflect light that is incident parallel to the reflection axis 12a without transmitting it. The directions of the reflection axis 12a and the transmission axis 12b can be confirmed, for example, by irradiating the film with light polarized in one direction using a spectrophotometer.

[0031] The reflective polarizing film 12 has different film elongation rates in the direction of the reflection axis 12a and the direction of the transmission axis 12b; specifically, it is less likely to elongate in the direction of the reflection axis 12a than in the direction of the transmission axis 12b. The reflective polarizing film 12 is stretched as described below and provided on the curved surface of the curved portion 11a. In the reflective polarizing optical element 10 shown in FIG. 1, the reflection axis 12a is arranged parallel to the extension direction of the minor axis 11c.

[0032] By arranging the reflection axis 12a and the extension direction of the minor axis 11c in this way, when the reflective polarizing film 12 is attached to the substrate 11, the length of the curved portion 11a in the direction of the reflection axis 12a, along which the reflective polarizing film 12 is less likely to stretch, is shortened. Therefore, when the reflective polarizing film 12 is attached, even in the direction of the reflection axis 12a, along which the reflective polarizing film 12 is less likely to stretch, the film can be attached to the curved portion of the substrate even if the amount of stretch of the reflective polarizing film 12 is small. Therefore, the area in which floating of the reflective polarizing film 12 may occur is located outside the curved portion 11a of the substrate 11. As a result, in the reflective polarizing optical element 10 according to this embodiment, it is possible to reduce the possibility of floating of the reflective polarizing film 12 at the curved portion 11a.

[0033] To reliably reduce the lift of the reflective polarizing film 12, it is preferable that the reflective polarizing film 12 be arranged so that the reflective axis 12a and the minor axis 11c of the curved portion 11a are parallel in a plan view in the optical axis direction of the substrate 11. However, in the case of the substrate shapes exemplified in FIG. 2(b) or 2(c), the extension direction of the minor axis 11c, taking into account the extension from the position corresponding to the reference point of the reflective polarizing film 12 to the edge of the substrate, may not coincide with the direction in which the extension decreases. To address this issue, in the design of the reflective polarizing optical element 10, the reflective polarizing film 12 is arranged and attached to the substrate so that the angle between the reflective axis 12a and the extension direction of the minor axis 11c is 30° or less. It has been discovered that this structure can reduce excessive extension of the reflective polarizing film 12. In other words, if the angle between the reflective axis 12a and the extension direction of the minor axis 11c is greater than 30°, the length of the curved portion 11a in the direction of the reflective axis 12a will not be long, causing excessive stretching in the reflective polarizing film 12 and making it impossible to expect the effects of this embodiment.

[0034] 1, for example, the radius of curvature of the curved surface of curved portion 11a to which reflective polarizing film 12 is attached is defined as R, and the length of major axis 11d of curved portion 11a is defined as L2. In this case, the half-open angle θ of the curved surface of curved portion 11a is defined by the following equation 1. Note that if the curved surface of curved portion 11a is aspherical, the radius of curvature R can be an optimal value, an approximate value, or the like obtained by optimal fitting using the least squares method. sinθ=(L2 / 2) / R (Equation 1) The half aperture angle θ can be set appropriately depending on the design of the substrate 11 that functions as a lens, but it is preferable that 0°<θ≦30° from the viewpoint of the substrate 11 functioning as a lens.

[0035] Furthermore, when the length of the minor axis 11c of the curved portion 11a is L1 and the angle between the reflection axis 12a and the minor axis 11c is φ, it is preferable that the length L1 of the minor axis 11c and the length L2 of the major axis 11d satisfy the following formula 2 for the half-open angle θ range of 5°≦θ≦30°. 0.2≦(L1 / cosφ) / L2≦-0.0128×θ+0.982 (Formula 2) Equation 2 indicates that the larger the half aperture angle θ, the more the reflective polarizing film 12 needs to be stretched before being attached, and that it is preferable to reduce the ratio of the length L1 of the minor axis 11c to the length L2 of the major axis 11d in order to prevent the reflective polarizing film 12 from floating. In other words, Equation 2 indicates that the larger the half aperture angle θ, the more it is preferable to shorten the length L1 of the minor axis 11c.

[0036] Next, a manufacturing method of the reflective polarizing optical element 10 according to this embodiment will be described with reference to FIGS. 3(a) to 3(h). The upper diagram of FIG. 3(a) and FIGS. 3(e) to 3(h) are diagrams illustrating the manufacturing method of the reflective polarizing optical element 10 according to this embodiment, and are cross-sectional views showing the schematic configuration of a manufacturing apparatus and the substrate 11 and other components held therein. Here, the case where the substrate 11 and other components shown in FIG. 1 are used will be described. The lower diagram of FIG. 3(a) is a plan view showing the substrate 11 and the reflective polarizing film 12 when viewed perpendicularly to the film surface from the second chamber 34 in the step shown in the upper diagram of FIG. 3(a). FIGS. 3(b) to 3(d) are cross-sectional views showing examples of the shape of the reflective polarizing film 12 when attached to the substrate 11.

[0037] As shown in FIG. 3(a) and other figures, the manufacturing apparatus used in this embodiment includes a first chamber 33, a second chamber 34, and a stage 32. The first chamber 33 and the second chamber 34 can be independently evacuated and depressurized. An opening that can connect to each other is provided at the top of the first chamber 33 and the corresponding bottom of the second chamber 34. Note that, although an example in which these chambers are arranged vertically is shown here, this arrangement is merely an example, and they can also be arranged horizontally or upside down.

[0038] In the actual film attachment process, first, as shown in FIG. 3(a), a substrate 11 having a minor axis 11c and a major axis 11d is placed in a first chamber 33. The substrate 11 is placed on a stage 32 having an elevation mechanism in the first chamber 33. A second chamber 34 is placed above the first chamber 33. A reflective polarizing film 12 is placed between the first chamber 33 and the second chamber 34, which are connected via the opening described above. At this time, the reflective polarizing film 12 is placed so as to directly face the substrate 11.

[0039] Here, the adhesive layer 13 and other components used in conjunction with the reflective polarizing film 12 when attaching the reflective polarizing film 12 to the substrate 11 will be described with reference to FIGS. 3(b) to 3(d). These figures schematically show cross sections of the reflective polarizing film 12 and other components. As shown in these figures, a uniform adhesive layer 13 can be provided on the surface of the reflective polarizing film 12 facing the substrate 11. In addition, a protective film 14 can be provided on the surface of the reflective polarizing film 12 (the surface opposite to the surface on which the adhesive layer 13 is formed). In this case, it is preferable that the glass transition temperature of the protective film 14 be lower than the glass transition temperature of the reflective polarizing film 12. The use of such a protective film 14 increases the usable strength of the reflective polarizing film 12 and makes it less likely that the reflective polarizing film 12 will tear when attached to the substrate 11.

[0040] Furthermore, the reflective polarizing film 12 is more expensive than general films. Therefore, from the viewpoint of reducing manufacturing costs, it is not appropriate to use a reflective polarizing film 12 that is much larger than the area of ​​the curved surface portion 11a of the substrate 11. In other words, the reflective polarizing film 12 only needs to be slightly larger than the substrate 11. Specifically, for example, the reflective polarizing film 12 only needs to have an area that is 1.5 to 2.5 times the area of ​​the curved surface portion 11a in a plan view in the optical axis direction of the substrate 11.

[0041] Here, if the size of the reflective polarizing film 12 is made as small as possible, it is necessary to ensure the size necessary for holding the reflective polarizing film 12 between the first chamber 33 and the second chamber 34. For this reason, as shown in FIG. 3(c), a support film 17 made of a separate material from the reflective polarizing film 12 may be attached to the reflective polarizing film 12. In this case, to ensure uniform deflection of the film when heated, it is preferable that the glass transition temperature of the support film 17 be equal to or about 20°C lower than the glass transition temperature of the reflective polarizing film 12.

[0042] 3(d), the support film 17 may be attached only to the outer periphery of the reflective polarizing film 12. The support film 17 can be peeled off from the reflective polarizing film 12 at an appropriate timing after the reflective polarizing film 12 is attached to the substrate 11.

[0043] In the step of attaching the reflective polarizing film 12, the above-described film is held between the first chamber 33 and the second chamber 34. At this time, the substrate 11 can be disposed at an angle so that a tangent to the center point of the minor axis 11c of the curved surface portion 11a of the substrate 11 is parallel to the reflective polarizing film 12. The means for disposing the substrate 11 at an angle is not particularly limited. For example, the substrate 11 can be disposed at an angle by installing a pedestal 32a having an inclined surface on the stage 32 that holds the substrate 11 and disposing the substrate 11 on the inclined surface. Alternatively, instead of disposing the substrate 11 at an angle, the reflective polarizing film 12 may be disposed at an angle so that a tangent to the center point of the minor axis 11c of the curved surface portion 11a is parallel to the reflective polarizing film 12.

[0044] This allows the reflective polarizing film 12 to be attached more evenly to the curved surface 11a. Furthermore, it is possible to more reliably prevent the reflective polarizing film 12 in a floating state from adhering to the curved surface 11a of the substrate 11, further reducing the possibility of the reflective polarizing film 12 floating.

[0045] Next, as shown in FIG. 3( e), the opening of the first chamber 33 and the opening of the second chamber 34 are connected so that the reflective polarizing film 12 is interposed between them. The first chamber 33 and the second chamber 34 are then evacuated to a vacuum, and the reflective polarizing film 12 is heated. The method for heating the reflective polarizing film 12 is not particularly limited, but examples include using an infrared heater to directly heat the reflective polarizing film 12 and heating the entire first chamber 33 and the second chamber 34 with a heater or the like. However, in the latter method, the substrate 11 is also heated. Heating the substrate 11 raises concerns about deformation of the substrate 11 due to heat, especially when the substrate 31 is made of a plastic material. Therefore, when the substrate 11 is heated, it is important to provide a heat insulating structure for the base 32 a of the substrate 11, and it is preferable to keep the temperature of the substrate 11 below 120°C, regardless of the temperature of the reflective polarizing film 12.

[0046] Next, after heating the reflective polarizing film 12 to a desired temperature, as shown in FIG. 3( f), the position of the substrate 11 is raised using a stage 32 with a lifting function until the adhesive layer 13 of the reflective polarizing film 12 contacts the curved surface 11a of the substrate 11. Next, only the inside of the second chamber 34 is opened to the atmosphere to increase the internal pressure, and if necessary, high-pressure gas is introduced into the second chamber 34 to pressurize the reflective polarizing film 12 and pressurize it against the substrate 11, including the curved surface 11a. In this way, the reflective polarizing film 12 is attached to the curved surface of the curved surface 11a of the substrate 11. The reflective polarizing film 12 is stretched by being pressed against the curved surface 11a and is provided on the curved surface of the curved surface 11a. Note that, if necessary, the heating and pressurization of the reflective polarizing film 12 may be continued for a certain period of time.

[0047] Here, the substrate 11 has a step portion 11e at the boundary between the curved portion 11a and the peripheral portion 11b at least on the minor axis 11c side. The reflective polarizing film 12 attached to the curved portion 11a can also have at least a portion attached to the step portion 11e. By attaching the reflective polarizing film 12 to the substrate 11 in this state, it is possible to suppress the reflective polarizing film from floating. This also provides a secondary effect of reducing film peeling during durability tests at high temperatures. The attachment range of the reflective polarizing film 12 to the step portion 11e may be, for example, from the end of the curved portion 11a corresponding to the minor axis to a range of 30° or more from the minor axis. An angle less than 30° may not adequately cover the range in which the reflective polarizing film 12 may float. By attaching the reflective polarizing film 12 to the step portion 11e beyond this range, it is also possible to secondary effect of reducing film peeling during durability tests at high temperatures.

[0048] 3(g), the heating and pressure application to the reflective polarizing film 12 is stopped, the pressure inside the second chamber 34 is returned to atmospheric pressure, and then the inside of the first chamber 33 is also opened to the atmosphere. Thereafter, the reflective polarizing film 12 and the substrate 11 to which it is attached are removed from the first chamber 33 and the second chamber 34.

[0049] Next, as shown in FIG. 3(h), the unnecessary reflective polarizing film 12 is cut off together with the adhesive layer 13 so as to leave only the reflective polarizing film 12 on the curved portion 11a of the substrate 11. The cutting method can be a method of cutting off the unnecessary reflective polarizing film 12 by applying a blade to the reflective polarizing film 12 along the outer edge of the curved portion 11a. Alternatively, the unnecessary reflective polarizing film 12 can be cut off by applying laser light to the reflective polarizing film 12 along the outer edge of the curved portion 11a. Note that these cutting methods are merely examples, and other known methods may also be used. By going through the above steps, a reflective polarizing optical element 10 in which the reflective polarizing film 12 is attached to the curved portion 11a of the substrate 11 can be manufactured.

[0050] 3(a) to 3(h), the manufacturing method of the reflective polarizing optical element 10 is not limited to the manufacturing method shown in Figures 3(a) to 3(h), and the reflective polarizing optical element 10 can be manufactured by other manufacturing methods. That is, in the manufactured reflective polarizing optical element 10, it is sufficient that the angle between the minor axis of the curved portion 11a passing through the reference point and the reflection axis 12a is 30° or less. When the reflective polarizing optical element 10 satisfies this condition, the occurrence of lifting of the reflective polarizing film 12 relative to the substrate 11 can be reduced, and peeling of the film can be reduced.

[0051] Here, another example of a manufacturing method will be described. For example, as in Example 8 described later, a reflective polarizing optical element 10 can be manufactured by attaching a reflective polarizing film 12 to a curved surface portion of a substrate having no distinction between a minor axis and a major axis, and then cutting off a predetermined end portion including the curved surface portion 11a of the substrate 11. In this case, for example, in the case of the reflective polarizing optical element 10 illustrated in FIG. 1, a substrate having a curved surface portion with an axisymmetric planar shape, such as a perfect circle, having no distinction between a minor axis 11c and a major axis 11d in a plan view seen in the optical axis direction of the substrate 11, is first arranged and prepared. Next, a reflective polarizing film 12 is attached to the curved surface of the curved surface portion. The attachment of the reflective polarizing film 12 can be performed in the same manner as the manufacturing method described above.

[0052] Next, at least one end of the substrate is cut off together with the reflective polarizing film 12 attached to that end in a direction that forms an angle of 30° or less with the reflective axis 12a of the reflective polarizing film 12 in a plan view seen in the optical axis direction of the substrate (here, a parallel direction). At this time, a peripheral edge is provided in the cut-off portion. The reflective polarizing optical element 10 illustrated in FIG. 1 can also be manufactured by the above steps.

[0053] Hereinafter, examples of actually fabricating reflective polarizing optical elements according to the present embodiment will be described. In the following examples, the reflective polarizing optical elements were evaluated by, for example, observing the edge condition using a microscope. Specifically, an area 2 mm inward from the outer periphery of the curved surface of the substrate was observed. If no lifting of 200 μm or more was observed, the element was evaluated as being good because it had no effect on peeling during a durability test under a high-temperature environment. Specifically, the microscope observation can be performed using, for example, a digital microscope VHX (manufactured by Keyence Corporation). Furthermore, as a durability test under high temperatures, a temperature cycle test was performed in which 30 cycles of 70°C for 30 minutes and -30°C for 30 minutes were repeated. After the durability test, the edge condition of the reflective polarizing optical element 10 was observed using a microscope to confirm whether peeling had progressed to an area 2 mm or more from the outer periphery.

[0054] Example 1 A reflective polarization optical element 10 and a manufacturing method for the reflective polarization optical element 10 according to Example 1 of the present invention will be described with reference to FIGS. 4(a) to 4(g). Example 1, described below, uses a substrate 11-5 made of a plastic primarily composed of cycloolefin copolymer (COC) molded by injection molding. The top two diagrams in FIG. 4(a) show the substrate 11-5 used in Example 1. The left diagram is a plan view of the substrate 11-5 as viewed in the optical axis direction, and the right diagram is a cross-sectional view of the substrate 11-5 taken along its minor axis 11c. As shown in FIG. 4(a), the substrate 11-5 is a convex lens with a curved surface portion 11a-5 having a minor axis 11c length L1 of 36 mm, a major axis 11d length L2 of 50 mm, and a half-open angle θ of 20°. Furthermore, a stepped portion 11e-5 is provided on the outer periphery of the curved surface portion 11a-5, with the lowest step height being 2 mm. Furthermore, the substrate 11-5 in this embodiment does not have a peripheral edge.

[0055] In this example, an IQPE (Image Quality Polarizer Enhanced) film manufactured by 3M was used as the reflective polarizing film 12. The two diagrams at the bottom of Figure 4(a) illustrate the reflective polarizing film 12 used in Example 1. The top diagram is a plan view showing the reflective polarizing film 12 in a planar view perpendicular to the film surface, and the bottom diagram is a cross-sectional view showing the cross section of the reflective polarizing film 12 along the reflection axis 12a. The reflective polarizing film 12 shown in Figure 4(a) has a square planar shape of 100 mm x 100 mm and a thickness of approximately 0.07 mm, and an adhesive layer 13 is provided on one side. Figure 4(b) is a plan view showing the substrate 11-5 and the reflective polarizing film 12 in the process shown in Figure 4(c) described below, viewed in a direction perpendicular to the film surface of the reflective polarizing film 12.

[0056] Figures 4(c) to 4(g) are cross-sectional views showing the manufacturing method of the reflective polarization optical element 10 according to Example 1 in the same format as Figure 3(a) and Figures 3(e) to 3(h). Note that components that have the same functions as the components of the manufacturing apparatus described using Figure 3(a) etc. are given the same reference numerals, and their description will be omitted here.

[0057] Regarding the substrate 11 and reflective polarizing film 12 described above, as shown in FIG. 4(c), the substrate 11-5 was placed in the first chamber 33, and the reflective polarizing film 12 was placed between the first chamber 33 and the second chamber 34. At this time, the reflective polarizing film 12 was placed directly opposite the substrate 11-5, with the adhesive layer 13 facing the substrate 11-5. The substrate 11-5 was also tilted so that the tangent to the center point of the minor axis 11c-5 was parallel to the reflective polarizing film 12. Furthermore, as shown in FIG. 4(c), the substrate 11-5 was placed so that the minor axis 11c of the curved surface portion 11a-5 of the substrate 11 and the reflection axis 12a of the reflective polarizing film 12 were approximately parallel (the angle φ was 0°, i.e., the angle φ was within ±2°).

[0058] Next, as shown in Figure 4(d), the first chamber 33 and the second chamber 34 were evacuated to a vacuum. Thereafter, the reflective polarizing film 12, which was disposed between the first chamber 33 and the second chamber 34, was heated by an infrared heater 38.

[0059] Heating by the infrared heater 38 continued until the temperature of the reflective polarizing film 12 reached 100°C. Then, as shown in FIG. 4(e), the stage 32 raised the substrate 11-5 until the curved portion 11a-5 contacted the adhesive layer 13 of the reflective polarizing film 12. Next, only the second chamber 34 was opened to the atmosphere. Compressed air was then introduced into the second chamber 34 to increase the pressure therein to 0.3 MPa, and the reflective polarizing film 12 was pressurized and pressed against the substrate 11 for 10 seconds. Then, as shown in FIG. 4(f), the heating and pressurization of the reflective polarizing film 12 were stopped, the second chamber 34 was returned to atmospheric pressure, and the first chamber 33 was also opened to the atmosphere.

[0060] After being opened to the atmosphere, the reflective polarizing film 12 and the substrate 11-5 to which it was attached were removed from the first chamber 33 and the second chamber 34. Next, as shown in Figure 4(g), a blade was applied to the reflective polarizing film 12 along the outer edge of the curved portion 11a-5 of the substrate 11-5 so as to leave only the reflective polarizing film 12 on the curved portion 11a-5 of the substrate 11-5, thereby cutting away the unnecessary reflective polarizing film 12 together with the adhesive layer 13. In this way, a reflective polarizing optical element 10-5 was produced in which the reflective polarizing film 12 was attached to the curved portion 11a-5 of the substrate 11-5.

[0061] The reflective polarizing optical element 10-5 of Example 1 was evaluated for floatation and the like by observing a region 2 mm from the outer periphery of the curved portion 11a-5 of the substrate 11-5 using an optical microscope VHX. As a result, no floatation of 200 μm or more in width was observed on the curved portion 11a-5 of the substrate 11-5. Furthermore, observation was also performed after a temperature cycle test, and it was confirmed that peeling had not progressed to a region 2 mm or more from the outer periphery of the curved portion 11a-5 of the substrate 11-5. Therefore, the reflective polarizing optical element 10 of Example 1 was evaluated as being good in terms of floatation and the like, as shown in Table 1 described later.

[0062] Example 2 In Example 2, the length of the minor axis, the length of the major axis, and the half aperture angle were changed in the shape of substrate 11-5 illustrated in Fig. 4(a) in Example 1. Specifically, a convex lens having a length L1 of the minor axis 11c of the curved portion of 46 mm, a length L2 of the major axis 11d of 50 mm, and a half aperture angle θ of the curved portion of 5° was used as the substrate. Note that, except for the changes in the dimensions of the shape of substrate 11-5, a reflective polarization optical element in Example 2 was manufactured in the same manner as in Example 1.

[0063] The reflective polarizing optical element of Example 2 was also evaluated in the same manner as the reflective polarizing optical element 10 of Example 1. As a result, no lifting of 200 μm or more in width was observed on the curved surface portion of the substrate. Furthermore, observation was also made after the temperature cycle test, and it was confirmed that peeling had not progressed to a region 2 mm or more from the outer periphery of the curved surface portion of the substrate. For this reason, the reflective polarizing optical element of Example 2 was evaluated as being good in terms of lifting and the like, as shown in Table 1.

[0064] Example 3 In Example 3, the length of the minor axis, the length of the major axis, and the half aperture angle were changed in the shape of substrate 11-5 exemplified in Figure 4(a) in Example 1. Specifically, a convex lens having a length L1 of the minor axis 11c of the curved portion of 40 mm, a length L2 of the major axis 11d of 50 mm, and a half aperture angle θ of the curved portion of 30° was used as the substrate. Note that, except for the changes in the dimensions of the shape of substrate 11-5, a reflective polarization optical element in Example 3 was manufactured in the same manner as in Example 1.

[0065] The reflective polarizing optical element of Example 3 was also evaluated in the same manner as the reflective polarizing optical element 10 of Example 1. As a result, no lifting of 200 μm or more in width was observed on the curved surface portion of the substrate. Furthermore, observation was also made after the temperature cycle test, and it was confirmed that peeling had not progressed to a region 2 mm or more from the outer periphery of the curved surface portion of the substrate. Therefore, the reflective polarizing optical element of Example 3 was evaluated as being good in terms of lifting and the like, as shown in Table 1.

[0066] Example 4 In Example 4, the shape of the substrate was changed to the shape shown in Fig. 2(a). Specifically, as shown in Fig. 5(a) of a similar format to Fig. 2(a), a convex lens was used as the substrate 11-2, with the length L1 of the minor axis 11c of the curved surface portion 11a-2 being 25 mm, the length L2 of the major axis 11d being 50 mm, and the half opening angle θ of the curved surface portion 11a-2 being 20°. In addition, a flat region with an outer diameter of 56 mm was provided as the peripheral edge portion 11b-2.

[0067] Next, a manufacturing method of the reflective polarizing optical element 10-2 in this example will be described. The left and right views of FIG. 5(b) correspond to the upper and lower views of FIG. 3(a), respectively. The left view of FIG. 5(b) is a cross-sectional view showing the manufacturing method of the reflective polarizing optical element 10 in Example 4. Therefore, components that have the same functions as those in the manufacturing apparatus described above are given the same reference numerals, and their description will be omitted here. In this example, the right view of FIG. 5(b) is a plan view showing the substrate 11-2 and the reflective polarizing film 12, viewed in a direction perpendicular to the film surface of the reflective polarizing film 12.

[0068] In Example 4, as shown in FIG. 5(b), a substrate 11-2 was placed in a first chamber 33, and a reflective polarizing film 12 was placed between the first chamber 33 and a second chamber 34. The reflective polarizing film 12 was placed directly opposite the substrate 11, with the adhesive layer 13 facing the substrate 11. The substrate 11-2 was placed on the stage 32 without using a base 32a and without tilting. The substrate 11-2 was placed so that the angle φ between the minor axis 11c of the curved surface portion 11a-2 and the reflection axis 12a of the reflective polarizing film 12 was 30°. In Example 4, a reflective polarizing optical element 10-2 was manufactured in the same manner as in Example 3, except that the shape of the substrate 11 was changed and the angle φ between the minor axis 11c of the curved surface portion 11a-2 and the reflection axis 12a of the reflective polarizing film 12 was set to 30°.

[0069] The reflective polarizing optical element 10-2 of Example 4 was also evaluated in the same manner as the reflective polarizing optical element 10-5 of Example 1. As a result, no lifting of 200 μm or more in width was observed on the curved surface portion 11a-2 of the substrate 11-2. Furthermore, observation after the temperature cycle test confirmed that peeling had not progressed to a region 2 mm or more from the outer periphery of the curved surface portion 11a-2 of the substrate 11-2. For this reason, the reflective polarizing optical element 10-2 of Example 4 was evaluated as being good in terms of lifting and the like, as shown in Table 1.

[0070] Example 5 In Example 5, the length of the minor axis, the length of the major axis, and the half aperture angle were changed in the shape of substrate 11-5 illustrated in Figure 4(a) in Example 1. Specifically, a concave lens was used in which the length L1 of the minor axis 11c of the curved portion was 36 mm, the length L2 of the major axis 11d was 50 mm, and the half aperture angle θ of the curved portion was 20°. Note that, except for the shape of substrate 11-5 being a concave lens and the various dimensions being changed, a reflective polarization optical element in Example 5 was manufactured in the same manner as in Example 1.

[0071] The reflective polarizing optical element of Example 5 was also evaluated in the same manner as the reflective polarizing optical element 10 of Example 1. As a result, no lifting of 200 μm or more in width was observed on the curved surface portion of the substrate. Furthermore, observation was also made after the temperature cycle test, and it was confirmed that peeling had not progressed to a region 2 mm or more from the outer periphery of the curved surface portion of the substrate. Therefore, the reflective polarizing optical element of Example 5 was evaluated as being good in terms of lifting, etc., as shown in Table 1.

[0072] Example 6 In Example 6, a substrate having a shape similar to that of the substrate 11-5 illustrated in FIG. 4(a) in Example 1 was used. The reflective polarizing film 12 was then heated to 120°C and bonded to the substrate 11-5 in that state. Raising the film temperature to 120°C during bonding further softens the reflective polarizing film 12, enabling favorable bonding. The state of the substrate 11-5 and the reflective polarizing film 12 during bonding is shown in FIG. 6(a) as a cross-sectional schematic diagram. As shown in FIG. 6(a), the reflective polarizing film 12 can be attached up to the stepped portion 11e-5 of the substrate 11-5. Next, a blade was applied to the reflective polarizing film 12 so as to leave only the reflective polarizing film 12 attached to the curved portion 11a-5 and the stepped portion 11e-5 of the substrate 11-5. The unnecessary reflective polarizing film 12 was then cut off together with the adhesive layer 13, as shown in FIG. 6(b). A reflective polarizing optical element was produced in the same manner as in Example 1, except for the temperature during lamination and the manner in which the film was cut off.

[0073] The reflective polarizing optical element 10-6 of Example 6 was also evaluated in the same manner as the reflective polarizing optical element 10 of Example 1. As a result, it was found that the reflective polarizing film 12 was attached not only to the curved portion 11a-5 of the substrate 11-5 but also to the stepped portion 11e-5, and no lifting of 200 μm or more in width was observed on the curved portion 11a-5 of the substrate 11-5. Furthermore, no lifting of 100 μm or more in width was observed. Furthermore, observation after the temperature cycle test confirmed that peeling had not progressed to a region 2 mm or more from the outer periphery of the curved portion 11a-5 of the substrate 11-5. Therefore, the reflective polarizing optical element 10-6 of Example 6 was evaluated as being even better in terms of lifting and the like than the reflective polarizing optical element exemplified in Example 1, as shown in Table 1.

[0074] Example 7 In Example 7, the shape of the substrate 11-2 illustrated in FIG. 5(a) in Example 4 was changed by changing the length of the minor axis, the length of the major axis, and the half-angle. Specifically, a convex lens was used as the substrate, with the length L1 of the minor axis 11c of the curved surface portion 11a-2 being 36 mm, the length L2 of the major axis 11d being 50 mm, and the half-angle θ of the curved surface portion 11a-2 being 20°. A flat peripheral edge portion 11b-2 with an outer diameter of 56 mm, concentric with the center of the curved surface portion 11a-2, was provided on the outer periphery of the curved surface portion 11a-2. Furthermore, between the curved surface portion 11a-2 and the peripheral edge portion 11b-2, a step portion 11e-2 with a height of 3 mm was provided on the straight portions at both ends of the minor axis 11c. Aside from these changes in the shape of the substrate, a reflective polarizing optical element 10-7 was manufactured in the same manner as in Example 6. FIG. 7 shows the manufactured reflective polarizing optical element 10-7, which is shown in a schematic manner similar to FIG. 5(a).

[0075] The reflective polarizing optical element 10-7 of Example 7 was also evaluated in the same manner as the reflective polarizing optical element 10-5 of Example 1. As a result, it was found that the reflective polarizing film 12 was attached not only to the curved portion 11a-2 of the substrate 11-2 but also to the stepped portion 11e-2, and no lifting of 200 μm or more in width was observed on the curved portion 11a-2 of the substrate 11-2. Furthermore, no lifting of 100 μm or more in width was observed. Furthermore, observation after the temperature cycle test confirmed that peeling had not progressed to a region 2 mm or more from the outer periphery of the curved portion 11a-2 of the substrate 11-2. Therefore, the reflective polarizing optical element 10-7 of Example 7 was evaluated as being even better in terms of lifting and the like than the reflective optical element exemplified in Example 1, as shown in Table 1.

[0076] Example 8 In Example 8, a substrate 11-8 having the shape shown in FIG. 8-1(a) was used. The two diagrams at the top of FIG. 8-1(a) are schematic diagrams of the substrate 11-8, with the left diagram being a plan view of the substrate 11-8 as seen in the optical axis direction, and the right diagram being a cross-sectional view of the substrate 11-8 along the minor axis 11c. As shown in FIG. 8-1(a), in plan view, the curved surface portion 11a-8 of the substrate 11-8 is a circle having a length L1 between the minor axis 11c and the major axis 11d of 50 mm, and is a convex lens with a half opening angle θ of 20°. Furthermore, the substrate 11-8 does not have a peripheral edge.

[0077] On the other hand, the same reflective polarizing film as in Example 1 was used for the reflective polarizing film 12, as shown in the two lower figures in Figure 8-1(a). Figure 8-1(a) is a diagram schematically showing the reflective polarizing film 12 used in Example 8, with the upper figure being a plan view of the reflective polarizing film 12 viewed in a direction perpendicular to the film surface, and the lower figure being a cross-sectional view showing the cross section of the reflective polarizing film 12 along the reflection axis 12a. The reflective polarizing film 12 used in this example has an adhesive layer 13 provided over the entire back surface.

[0078] Next, a manufacturing method of the reflective polarizing optical element 10-8 according to this example will be described using FIGS. 8-2(c) to 8-4(h). FIGS. 8-2(c) to 8-3(g) illustrate the steps of the manufacturing method of the reflective polarizing optical element 10-8 according to this example in the same manner as the steps illustrated in the description of the manufacturing process of the reflective polarizing optical element 10 exemplified in Example 1. That is, they are cross-sectional schematic diagrams illustrating the steps of the manufacturing method of the reflective polarizing optical element 10-8. Also, FIG. 8-1(b) is a plan view showing the positional relationship between the substrate 11-8 and the reflective polarizing film 12 in the step illustrated in FIG. 8-2(c), as viewed in a direction perpendicular to the film surface of the reflective polarizing film 12. FIG. 8-4(h) illustrates the final step in the manufacturing method of the reflective polarizing optical element 10-8 according to this example, showing plan views and cross-sectional views of the reflective polarizing optical element 10-8 before and after the final step.

[0079] In this example, when manufacturing the reflective polarizing optical element 10-8, first, as shown in FIG. 8-2(c), the above-mentioned substrate 11-8 was placed in the first chamber 33. Furthermore, the reflective polarizing film 12 was placed between the first chamber 33 and the second chamber 34. At this time, the reflective polarizing film 12 was placed directly opposite the substrate 11-8, with the adhesive layer 13 facing the substrate 11-8. Furthermore, since the back surface of the substrate 11-8 is a flat surface perpendicular to the optical axis, the base 32a used in Example 1 was not used and the substrate was placed on the stage 32 without tilting. Note that the direction of the reflection axis 12a of the reflective polarizing film 12 is not particularly specified in this example.

[0080] Next, as shown in Figure 8-2(d), the first chamber 33 and the second chamber 34 were evacuated to a vacuum, and the reflective polarizing film 12, which was disposed between the first chamber 33 and the second chamber 34, was heated by an infrared heater 38.

[0081] After heating the reflective polarizing film 12 to 100°C, the stage 32 was used to raise the position of the substrate 11-8 until the curved portion 11a-8 of the substrate 11-8 contacted the adhesive layer 13 of the reflective polarizing film 12, as shown in FIG. 8-2(e). Next, only the second chamber 34 was opened to the atmosphere. After that, compressed air was introduced into the second chamber 34 to increase the pressure inside the second chamber 34 to 0.3 MPa, and the reflective polarizing film 12 was pressurized and pressed against the substrate 11 for 10 seconds. After that, as shown in FIG. 8-2(f), the heating and pressurization of the reflective polarizing film 12 were stopped, the second chamber 34 was returned to atmospheric pressure, and the first chamber 33 was also opened to the atmosphere.

[0082] Next, as shown in Figure 8-3(g), the reflective polarizing film 12 and the substrate 11-8 to which it was attached were removed from the first chamber 33 and the second chamber 34. Next, a blade was applied to the reflective polarizing film 12 along the outer edge of the curved portion 11a-8 so as to leave only the reflective polarizing film 12 on the curved portion 11a-8 of the substrate 11-8, thereby cutting away the unnecessary reflective polarizing film 12 together with the adhesive layer 13. This resulted in a reflective polarizing optical element 10a that was circular in plan view.

[0083] The reflective polarizing optical element 10 manufactured as described above was observed in a region extending 7 mm from the outer periphery of the curved portion 11a-8 of the substrate 11-8, as in Example 1. Multiple floats of 200 μm or more in width were confirmed on the curved portion 11a-8 of the substrate 11-8. The floats were found only near both ends of the curved portion 11a-8 in the direction of the reflection axis 12a of the reflective polarizing film 12. Therefore, in Example 8, as shown in FIG. 8-4(h), in the above-mentioned reflective polarizing optical element 10a, both ends of the curved portion 11a-8 in the direction parallel to the reflection axis 12a were cut off by 7 mm. In this way, in Example 8, the reflective polarizing optical element 10-8 was manufactured by attaching the reflective polarizing film 12 to the curved portion 11a-8 of the substrate 11-8 and then cutting off the portions where floats had occurred.

[0084] The reflective polarizing optical element 10-8 of Example 8 was also evaluated in the same manner as the reflective polarizing optical element 10 of Example 1. As a result, no lifting of 200 μm or more in width was observed on the curved surface of the substrate. Furthermore, observation after the temperature cycle test was also conducted, and it was confirmed that peeling had not progressed to a region 2 mm or more from the outer periphery of the curved surface of the substrate. Therefore, the reflective polarizing optical element 10-8 of Example 8 was evaluated as being good in terms of lifting, etc., as shown in Table 1.

[0085] (Comparative Example 1) Comparative Example 1 describes a case where a substrate of a convex lens having the same minor and major axes of 50 mm and a half-open angle θ of 20° was used. Specifically, the substrate 11-8 having the shape shown in FIG. 8-1(a) described in Example 8 was used. As described above, the substrate 11-8 is a convex lens having a circular shape in plan view, with the minor axis 11c of the curved surface portion 11a-8 having a length L1 of 50 mm and the major axis 11d having a length L2 of 50 mm, and a half-open angle θ of 20°. The curved surface portion 11a-8 also has a shape without a peripheral edge. Regarding the manufacturing method, the reflective polarizing optical element 10 in Comparative Example 1 was manufactured in the same manner as in Example 1, except that the shape of the substrate was changed and the direction of the reflection axis 12a was not particularly specified when the reflective polarizing film 12 was arranged.

[0086] The reflective polarizing optical element of Comparative Example 1 was also evaluated in the same manner as the reflective polarizing optical element 10-5 of Example 1. As a result, 300 μm-wide lifting was confirmed at both ends of the curved surface portion 11a-8 of the substrate 11-8 in the reflection axis direction. Furthermore, observation was also made after the temperature cycle test, and it was confirmed that peeling had progressed to a region 2 mm or more from the outer periphery of the curved surface portion 11a-8 of the substrate 11-8. For this reason, the reflective polarizing optical element 10 of Comparative Example 1 was evaluated as defective in terms of lifting and the like, as shown in Table 1. [Table 1]

[0087] [Second embodiment] The reflective polarizing optical element according to the first embodiment described above can be applied to various devices and apparatuses such as optical equipment, display devices, imaging devices, etc. In this embodiment, optical equipment and display devices will be described as specific application examples of the reflective polarizing optical element according to the first embodiment.

[0088] (optical equipment) Specific application examples of the reflective polarizing optical element according to the first embodiment include lenses constituting optical equipment (photography optical systems) for cameras and video cameras, and lenses constituting optical equipment (projection optical systems) for liquid crystal projectors. Fig. 9 is a schematic diagram showing an example of a preferred embodiment of an optical equipment using the reflective polarizing optical element according to the first embodiment. The optical system of optical equipment 100a includes a plurality of lenses arranged in a housing 101a, and the reflective polarizing optical element 10 according to the first embodiment can be used for at least one of these lenses.

[0089] (display device) 10(a) to 10(c) are schematic diagrams showing the configuration of a head-mounted display (HMD) 100b, which is an example of a preferred embodiment of a display device using the reflective polarization optical element according to the first embodiment. Fig. 10(a) is a side view showing the HMD 100b. Fig. 10(b) is a front view showing the HMD 100b. Fig. 10(c) is a schematic diagram showing the optical system of the HMD 100b.

[0090] 10(a) and 10(b), the HMD 100b has a housing 101b, a wearing device 102, and display units 103 for the left and right eyes. Each display unit 103 is provided inside the housing 101b. The HMD 100b is worn on the user's head by the wearing device 102 so that the display units 103 for the left and right eyes are positioned corresponding to the user's left and right eyes, respectively.

[0091] As shown in FIG. 10(c), each display unit 103 includes a display panel 104 and optical systems 10, 105, and 106. The optical system may include, for example, the reflective polarizing optical element according to the first embodiment. The display panel 104 is a display unit including an organic electroluminescence (EL) panel, a liquid crystal panel, or the like, and displays an image for the corresponding left or right eye. The optical systems 10, 105, and 106 focus the image light emitted from the display panel 104 at the position of the user's eyes. Depending on the design of the HMD 100b, the optical systems 10, 105, and 106 may include transmissive optical elements such as convex lenses or concave lenses, reflective optical elements such as concave mirrors, mirrors, half mirrors, and optical path changing elements such as phase difference optical elements. The reflective polarizing optical element 10 is installed between the optical system 105 and the optical system 106 and the eyes. The reflective polarizing optical element 10, together with optical systems 105 and 106, constitutes an optical system that guides image light, which is light emitted from the display panel 104, to the user's eyes, and functions as at least one of the optical elements, i.e., lenses, in the optical system.

[0092] Although the embodiment using an HMD has been described as a display device to which the reflective polarizing optical element is applied, the display device according to the present embodiment is not limited to this example. For example, the reflective polarizing optical element 10 according to the present embodiment can also be used in a display device such as a projector, as in the above-described example.

[0093] As described above, the reflective polarizing optical element (10, 10-5, 10-6, 10-8) according to the present invention includes a substrate (11, 11-2 to 11-8) and a reflective polarizing film 12 attached to the substrate. The substrate has a curved surface portion (11a, 11a-2 to 11a-5, 11a-8) having a first diameter (minor diameter 11c) in a plan view of the substrate in the optical axis direction and a second diameter (major diameter 11d) in a plan view that is longer than the first diameter, and the surface of the substrate forms a curved surface. The reflective polarizing film 12 has a transmission axis 12b and a reflection axis 12a and is attached to the curved surface of the curved surface portion. The reflective polarizing film 12 is arranged such that the extension direction of the reflection axis 12a and the extension direction of the first diameter (minor diameter 11c) are parallel to each other in the plan view. The extension direction of the reflection axis 12a and the extension direction of the first diameter may be arranged so that the angle between them is 30° or less. Note that, in the case of the substrate 11 illustrated in Fig. 1, for example, this condition can also be understood as the diameter extending in a direction perpendicular to the extension direction of the longest diameter (major diameter 11d) of the curved surface portion 11a in a plan view.

[0094] This allows the length of the reflective polarizing film 12 to be stretched and attached in the extension direction of the reflective axis 12a, which is a direction in which the film is relatively stretch-resistant, to be kept short. Therefore, the load on the reflective polarizing film 12 due to stretching is relatively reduced, reducing the occurrence of starting points for floating and peeling. To more effectively reduce the occurrence of floating and peeling, it is preferable to align the extension direction of the first diameter with the extension direction of the reflective axis 12a. However, if the angle between these directions is 30° or less, the amount of stretching of the reflective polarizing film 12 can be set to a level that is expected to reduce load to a certain extent, thereby reducing the occurrence of floating and peeling. If the angle is greater than 30°, the difference with the direction of the second diameter becomes small, making it difficult to predict the relative effectiveness of load reduction depending on the attachment direction of the reflective polarizing film 12.

[0095] The curved surface portions (11a, 11a-2, 11a-3, 11a-5) of the substrates (11, 11-2, 11-3, 11-5) can be shaped as being surrounded by arcs and lines in a planar view. In this case, the arcs can be multiple arcs each constituting part of the same circle in a planar view, and the lines can be lines connecting the ends of adjacent arcs among the multiple arcs. In such a case, the first diameter corresponds to the shortest diameter among the diameters passing through the center point O of the circle in a planar view. Furthermore, the second diameter corresponds to the diameter that passes through the center point O and extends in a direction perpendicular to the extension direction of the first diameter in a planar view.

[0096] Here, the curved surface portion may be configured with an outer shape including a plurality of arcs with different curvatures, such as the curved surface portion 11a-4 illustrated in Fig. 2(c). In this case, the first diameter (minor diameter 11c) may be the shortest diameter passing through the centroid point C of the outer shape in a plan view. Furthermore, when the half-open angle of the curved surface is θ, it is preferable that θ satisfies 0°<θ≦30°. When the substrate satisfies this condition in designing a lens, the substrate can function as a lens.

[0097] Here, the angle between the first diameter (minor diameter 11c) and the reflective axis 12a is φ, the length of the first diameter is L1, and the length of the second diameter is L2. In this case, it is preferable that L1 and L2 satisfy the relationship 0.2≦(L1 / cosφ) / L2≦−0.0128×θ+0.982 under the condition of 5°≦θ≦30°. To reduce the possibility of the reflective polarizing film 12 floating, it is preferable to reduce the ratio of the length L1 of the minor diameter 11c to the length L2 of the major diameter 11d. However, the lens structure limits how small this ratio can be. By setting the half-open angle θ within this range, it is possible to broaden the constraints on L1 in the design of the reflective polarizing optical element.

[0098] As shown in FIG. 1 , the substrate 11 may have a stepped portion 11e extending continuously from the outer periphery of the curved portion 11a in the optical axis direction. The reflective polarizing film 12 may be attached from the outer periphery of the curved portion 11a to a portion of the stepped portion 11e. In this case, the reflective polarizing film 12 may be attached to a portion or all of the connecting portion of the stepped portion 11e over the entire outer periphery of the curved portion 11a. In this case, if the reflective polarizing film 12 is attached to a portion of the periphery, for example, a portion whose minor axis is greater than ±15° from the center of the periphery, then attachment to the stepped portion 11e can be expected to reduce the possibility of floating or other problems. The substrate 11 may also have a peripheral portion 11b provided on the periphery of the curved portion 11a. This peripheral portion can be used, for example, to fix the reflective polarizing optical element 10. The reflective polarizing film 12 may also be attached to the curved surface via an adhesive layer 13.

[0099] The present invention can also be used to configure an optical device. For example, an optical device 100a illustrated in FIG. 9 includes a housing 101a and an optical system having at least one optical element disposed within the housing. In this case, the optical element can include the above-described reflective polarization optical element 10. The present invention can also be used to configure a display device. For example, a display device (HMD 100b) illustrated in FIGS. 10(a) to 10(c) can include a housing 101b, optical systems (10, 105, 106), and a display unit (display panel 104). The optical system can include at least one optical element (10) disposed within the housing 101b. The display unit emits light guided by the optical system.

[0100] The present invention also provides a method for manufacturing a reflective polarizing optical element. This manufacturing method uses a substrate (11, 11-2, 11-3, 11-5) having a first diameter (minor diameter 11c) in a planar view in the optical axis direction and a second diameter (major diameter 11d) in a planar view that is longer than the first diameter (11c). As described above, the reflective polarizing film 12 is attached to a curved surface portion (11a, 11a-2, 11a-3, 11a-5) of the substrate, whose surface forms a curved surface. The reflective polarizing film 12, which has a transmission axis 12b and a reflection axis 12a, is arranged so that the extension direction of the reflection axis 12a and the extension direction of the first diameter are parallel to each other in a planar view. The reflective polarizing film 12 may also be attached so that the extension direction of the reflection axis 12a and the extension direction of the first diameter form an angle of 30° or less.

[0101] The reflective polarizing film 12 is attached to the curved surface portions (11a, 11a-2, 11a-3, 11a-5) by being pressed against the substrates (11, 11-2, 11-3, 11-5). In the illustrated manufacturing method, when attaching the reflective polarizing film 12, the substrate 11 can be positioned so that a tangent to the center point of the first diameter (minor diameter 11c) of the curved surface portion 11a is parallel to the reflective polarizing film 12. The reflective polarizing film 12 can also be attached to the curved surface portion 11a-5 in a heated state (e.g., FIG. 4(d)). The substrate 11 can have a stepped portion 11e extending continuously from the outer periphery of the curved surface portion 11a in the optical axis direction, and the reflective polarizing film 12 can be attached from the outer periphery of the curved surface portion 11a-5 to a part of the stepped portion 11e-5.

[0102] 8(a) to 8(h). This manufacturing method can include the steps of attaching a reflective polarizing film 12 to a substrate 11-8 and cutting out the curved portion of the curved portion 11a-8 of the substrate 11-8 together with the attached reflective polarizing film 12. In this manufacturing method, the cutting involves cutting off at least one end of the substrate 11-8, including the curved portion 11a-8, in a direction that forms an angle with the reflection axis 12a of 30° or less in a plan view in the optical axis direction.

[0103] The manufacturing method described above can produce, for example, the reflective polarizing optical element exemplified in the first embodiment. In the reflective polarizing optical element, it is possible to reduce the occurrence of lifting of the film in the peripheral portion.

[0104] The above-mentioned invention includes the following configurations and methods. (Configuration 1) a substrate having a curved surface portion that has a first diameter in a plan view seen in the optical axis direction and a second diameter in the plan view that is longer than the first diameter, and whose surface forms a curved surface; a reflective polarizing film having a transmission axis and a reflection axis, attached to the curved surface of the curved surface portion, wherein the extension direction of the reflection axis and the extension direction of the first diameter are arranged parallel to each other in the plan view; A reflective polarizing optical element comprising: (Configuration 2) The reflective polarizing optical element of configuration 1, wherein the curved surface portion has a shape in the planar view that is surrounded by a plurality of arcs, each of which constitutes part of the same circle in the planar view, and a line connecting ends of adjacent arcs among the plurality of arcs, and the first diameter is the shortest diameter among diameters that pass through a center point of the circle in the planar view. (Configuration 3) a substrate having a curved surface portion that has a first diameter in a plan view seen in the optical axis direction and a second diameter in the plan view that is longer than the first diameter, and whose surface forms a curved surface; a reflective polarizing film having a transmission axis and a reflection axis, attached to the curved surface of the curved surface portion, the reflective polarizing film being arranged such that, in the planar view, an angle formed between an extension direction of the reflection axis and an extension direction of the first diameter is 30° or less; The reflective polarizing optical element, wherein the first diameter is the shortest diameter of the substrate in the plan view. (Configuration 4) The reflective polarizing optical element according to configuration 3, wherein the curved surface portion is configured by an outer shape including a plurality of arcs with different curvatures, and the first diameter is the shortest diameter among the diameters passing through the centroid of the outer shape in the planar view. (Configuration 5) 5. The reflective polarizing optical element according to configuration 4, wherein the second diameter is the longest diameter passing through the centroid of the outer shape in the plan view. (Configuration 6) a substrate having a curved surface portion that has a first diameter in a plan view seen in the optical axis direction and a second diameter in the plan view that is longer than the first diameter, and whose surface forms a curved surface; a reflective polarizing film having a transmission axis and a reflection axis, attached to the curved surface of the curved surface portion, the reflective polarizing film being arranged such that, in the planar view, an angle formed between an extension direction of the reflection axis and an extension direction of the first diameter is 30° or less; a first diameter that is the shortest diameter passing through a center point of the circle in the planar view, the first diameter being the shortest diameter among the diameters that pass ... (Configuration 7) 7. The reflective polarizing optical element according to configuration 6, wherein the second diameter is a diameter that passes through the center point and extends in a direction perpendicular to the extension direction of the first diameter in the plan view. (Configuration 8) 7. The reflective polarizing optical element according to configuration 6, wherein θ is a half-open angle of the curved surface, and θ satisfies 0°<θ≦30°. (Configuration 9) When the angle between the first diameter and the reflection axis is φ, the length of the first diameter is L1, and the length of the second diameter is L2, L1 and L2 are 0.2≦(L1 / cosφ) / L2≦-0.0128×θ+0.982 9. The reflective polarizing optical element according to configuration 8, which satisfies the above. (Configuration 10) the substrate has a step portion extending continuously from the outer periphery of the curved surface portion, 10. The reflective polarizing optical element according to any one of configurations 1 to 9, wherein the reflective polarizing film is attached from the outer periphery of the curved surface portion to a part of the step portion. (Configuration 11) 11. The reflective polarizing optical element according to any one of configurations 1 to 10, wherein the substrate has a peripheral portion provided on the periphery of the curved surface portion. (Configuration 12) 12. The reflective polarizing optical element according to any one of configurations 1 to 11, wherein the reflective polarizing film is attached to the curved surface via an adhesive layer. (Configuration 13) The housing and an optical system having at least one optical element disposed within the housing; 13. An optical instrument, wherein the optical element includes the reflective polarizing optical element according to any one of configurations 1 to 12. (Configuration 14) The housing and an optical system having at least one optical element disposed within the housing; a display unit that emits light guided by the optical system, 13. A display device, wherein the optical element includes the reflective polarizing optical element according to any one of configurations 1 to 12. (Method 1) A method for manufacturing a reflective polarizing optical element, comprising: attaching a reflective polarizing film having a transmission axis and a reflection axis to a curved portion of a surface of a substrate having a first diameter in a plan view in an optical axis direction and a second diameter in the plan view that is longer than the first diameter, In the bonding step, the bonding is performed so that the extension direction of the reflection axis and the extension direction of the first diameter are parallel to each other in the plan view. (Method 2) A method for manufacturing a reflective polarizing optical element, comprising: attaching a reflective polarizing film having a transmission axis and a reflection axis to a curved portion of a surface of a substrate having a first diameter in a plan view in an optical axis direction and a second diameter in the plan view that is longer than the first diameter, the curved surface portion has a shape in the plan view that is surrounded by a plurality of arcs each constituting a part of the same circle in the plan view and a line connecting ends of adjacent arcs among the plurality of arcs, and the first diameter is the shortest diameter among diameters that pass through a center point of the circle in the plan view, In the bonding step, the bonding is performed so that the angle between the extension direction of the reflection axis and the extension direction of the first diameter is 30° or less in the planar view. (Method 3) 3. The method for producing a reflective polarizing optical element according to Method 1 or 2, comprising pressing the reflective polarizing film against the substrate, thereby attaching the reflective polarizing film to the curved surface. (Method 4) A method for manufacturing a reflective polarizing optical element described in any one of methods 1 to 3, wherein when the reflective polarizing film is attached to the curved surface portion, the substrate is positioned so that a tangent to the center point of the first diameter of the curved surface portion is parallel to the reflective polarizing film. (Method 5) 5. The method for producing a reflective polarizing optical element according to any one of Methods 1 to 4, wherein the reflective polarizing film is attached to the curved surface portion in a heated state. (Method 6) the substrate has a step portion extending continuously from the outer periphery of the curved surface portion, 6. The method for producing a reflective polarizing optical element according to any one of methods 1 to 5, wherein the reflective polarizing film is attached from the outer periphery of the curved surface portion to a part of the step portion. (Method 7) A reflective polarizing film having a transmission axis and a reflection axis is attached to a curved surface portion of a substrate having a curved surface portion; cutting off at least one end of the substrate including the curved surface portion in a direction that is included in a range in which the angle formed with the reflection axis is 30° or less in a plan view in the optical axis direction; A method for manufacturing a reflective polarizing optical element, comprising:

[0105] Although the present invention has been described above with reference to embodiments and examples, the present invention is not limited to the above-described embodiments and examples. Inventions modified within the scope of the present invention and inventions equivalent to the present invention are also included in the present disclosure. Furthermore, the above-described examples can be combined as appropriate within the scope of the present invention. [Explanation of symbols]

[0106] 10 Reflective polarizing optical elements 11 Circuit Board 11a Curved part 11b Periphery 11c Minor diameter 11d major axis 11e Step 12 Reflective polarizing film 13 Adhesive layer 14 Protective film 17 Support film 32 stages 32a Pedestal 33 First Chamber 34 Second Chamber 100 Head-Mounted Display (HMD) 101 Case 102 Wearing equipment 103 Display Unit 104 Display Panel 105, 106 Optical system

Claims

1. a substrate having a curved surface portion that has a first diameter in a plan view seen in the optical axis direction and a second diameter in the plan view that is longer than the first diameter, and whose surface forms a curved surface; a reflective polarizing film having a transmission axis and a reflection axis, attached to the curved surface of the curved surface portion, wherein the extension direction of the reflection axis and the extension direction of the first diameter are arranged parallel to each other in the plan view; A reflective polarizing optical element comprising:

2. 2. The reflective polarizing optical element according to claim 1, wherein the curved surface portion has a shape in the planar view that is surrounded by a plurality of arcs, each of which constitutes part of the same circle in the planar view, and a line connecting ends of adjacent arcs among the plurality of arcs, and the first diameter is the shortest diameter among diameters that pass through a center point of the circle in the planar view.

3. a substrate having a curved surface portion that has a first diameter in a plan view seen in the optical axis direction and a second diameter in the plan view that is longer than the first diameter, and whose surface forms a curved surface; a reflective polarizing film having a transmission axis and a reflection axis, attached to the curved surface of the curved surface portion, the reflective polarizing film being arranged such that, in the planar view, an angle formed between an extension direction of the reflection axis and an extension direction of the first diameter is 30° or less; The reflective polarizing optical element, wherein the first diameter is the shortest diameter of the substrate in the plan view.

4. 4. The reflective polarizing optical element according to claim 3, wherein the curved surface portion is configured by an outer shape including a plurality of arcs with different curvatures, and the first diameter is the shortest diameter among diameters passing through a centroid point of the outer shape in the planar view.

5. The reflective polarizing optical element according to claim 4 , wherein the second diameter is the longest diameter passing through a centroid of the outer shape in the plan view.

6. a substrate having a curved surface portion that has a first diameter in a plan view seen in the optical axis direction and a second diameter in the plan view that is longer than the first diameter, and whose surface forms a curved surface; a reflective polarizing film having a transmission axis and a reflection axis, attached to the curved surface of the curved surface portion, the reflective polarizing film being arranged such that, in the planar view, an angle formed between an extension direction of the reflection axis and an extension direction of the first diameter is 30° or less; a first diameter that is the shortest diameter passing through a center point of the circle in the planar view, the first diameter being the shortest diameter among the diameters that pass ...

7. The reflective polarizing optical element according to claim 6 , wherein the second diameter is a diameter that passes through the center point and extends in a direction perpendicular to an extension direction of the first diameter in the plan view.

8. 7. The reflective polarizing optical element according to claim 6, wherein θ is a half-open angle of the curved surface, and θ satisfies 0°<θ≦30°.

9. When the angle between the first diameter and the reflection axis is φ, the length of the first diameter is L1, and the length of the second diameter is L2, L1 and L2 are 0.2≦(L1 / cosφ) / L2≦-0.0128×θ+0.982 The reflective polarizing optical element according to claim 8 , which satisfies the following:

10. the substrate has a step portion extending continuously from the outer periphery of the curved surface portion, The reflective polarizing optical element according to claim 1 , wherein the reflective polarizing film is attached from an outer periphery of the curved surface portion to a part of the step portion.

11. The reflective polarizing optical element according to claim 1 , wherein the substrate has a peripheral edge portion provided on a peripheral edge of the curved surface portion.

12. The reflective polarizing optical element according to claim 1 , wherein the reflective polarizing film is attached to the curved surface via an adhesive layer.

13. The housing and an optical system having at least one optical element disposed within the housing; An optical instrument, wherein the optical element comprises a reflective polarizing optical element according to any one of claims 1 to 9.

14. The housing and an optical system having at least one optical element disposed within the housing; a display unit that emits light guided by the optical system, A display device, wherein the optical element comprises a reflective polarizing optical element according to claim 1 .

15. A method for manufacturing a reflective polarizing optical element, comprising: attaching a reflective polarizing film having a transmission axis and a reflection axis to a curved portion of a surface of a substrate having a first diameter in a plan view in an optical axis direction and a second diameter in the plan view that is longer than the first diameter, In the bonding step, the bonding is performed so that the extension direction of the reflection axis and the extension direction of the first diameter are parallel to each other in the plan view.

16. A method for manufacturing a reflective polarizing optical element, comprising: attaching a reflective polarizing film having a transmission axis and a reflection axis to a curved portion of a surface of a substrate having a first diameter in a plan view in an optical axis direction and a second diameter in the plan view that is longer than the first diameter, the curved surface portion has a shape in the plan view that is surrounded by a plurality of arcs each constituting a part of the same circle in the plan view and a line connecting ends of adjacent arcs among the plurality of arcs, and the first diameter is the shortest diameter among diameters that pass through a center point of the circle in the plan view, In the bonding step, the bonding is performed so that an angle between the extension direction of the reflection axis and the extension direction of the first diameter is 30° or less in the planar view.

17. The method for manufacturing a reflective polarizing optical element according to claim 15 or 16, comprising: attaching the reflective polarizing film to the curved surface by pressing the reflective polarizing film against the substrate.

18. 17. The method for manufacturing a reflective polarizing optical element according to claim 15, wherein, when the reflective polarizing film is attached to the curved surface portion, the substrate is positioned so that a tangent to the curved surface portion at a center point of the first diameter is parallel to the reflective polarizing film.

19. The method for producing a reflective polarizing optical element according to claim 15 or 16, wherein the reflective polarizing film is attached to the curved surface portion in a heated state.

20. the substrate has a step portion extending continuously from the outer periphery of the curved surface portion, The method for manufacturing a reflective polarizing optical element according to claim 15 or 16, wherein the reflective polarizing film is attached from the outer periphery of the curved surface portion to a part of the step portion.

21. A reflective polarizing film having a transmission axis and a reflection axis is attached to a curved surface portion of a substrate having a curved surface portion; cutting off at least one end of the substrate including the curved surface portion in a direction that is included in a range in which the angle formed with the reflection axis is 30° or less in a plan view in the optical axis direction; A method for manufacturing a reflective polarizing optical element, comprising:

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