Method for manufacturing an optical device

Abstract

To provide a method of manufacturing an optical device in which a photo-curable resin composition can be securely cured.SOLUTION: A method of manufacturing an optical device 1 which has an optical member 2 and a transparent panel 4 stuck together across a curable resin layer 3 comprises the steps of: forming a wall part 12 which encircles a formation region of the curable resin layer 3 and is provided with at least one opening part 13 on one of the optical member 2 and transparent panel 4; sticking the optical member 2 and transparent panel 4 together to form a stuck body 10 having a resin-filled space 14 enclosed with the wall part 12 between the optical member 2 and transparent panel 4; filling the resin-filled space 14 of the stuck body 10 with a photo-curable resin composition 30; and curing the photo-curable resin composition 30 into a cured resin layer 3.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] This technology is a method for manufacturing a display device in which an optical member such as a liquid crystal display panel and a transparent panel such as a protective sheet that is attached to the display surface side of the optical member are attached via a cured resin layer. light The present invention relates to a method for manufacturing an optical device. [Background technology]

[0002] 2. Description of the Related Art Conventionally, optical devices such as liquid crystal display devices used in information terminals such as smartphones and car navigation systems have a light-transmitting cured resin layer provided between an optical component such as a liquid crystal display panel and a transparent panel that protects the optical component, in order to reduce the thickness and improve visibility.

[0003] As a method for forming a cured resin layer, for example, a method is used in which a photocurable resin composition is applied to a transparent panel to form a curable resin layer, an optical component such as a liquid crystal display panel or an organic EL panel is laminated via this curable resin layer, and then the curable resin layer is cured (Patent Document 1).

[0004] Methods of applying the photocurable resin composition to a transparent panel include a method of discharging the composition from a moving slit nozzle onto the entire width of the surface of the transparent panel, and a method of applying the composition by screen printing. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2015-52795 A Summary of the Invention [Problem to be solved by the invention]

[0006] However, in the conventional manufacturing methods described above, when the optical components or transparent panels become large, problems arise such as the need for a large vacuum lamination device during lamination and a large autoclave after lamination.

[0007] In addition, when a photocurable resin composition is applied to a light-shielding portion provided on a transparent panel, the curing light irradiated from the front side of the transparent panel is blocked by the light-shielding portion, inhibiting curing, so a so-called side cure is performed in which the curing light is irradiated from the side of the transparent panel.

[0008] Here, in recent years, optical devices have been proposed in which a plurality of optical members are arranged close to each other and a single transparent panel is laminated. As shown in Fig. 14, in such an optical device 50, light-shielding portions 53 corresponding to the optical members 52a, 52b are formed adjacent to a transparent panel 51. Since three sides of each light-shielding portion 53 face the side surface of the transparent panel 51, side curing is possible, but side curing is difficult in the portion where the optical members 52a, 52b are adjacent to each other.

[0009] Therefore, the present technology has an object to provide an optical device and a manufacturing method thereof that do not require a large vacuum lamination device, autoclave treatment, or side cure process even for a large optical device, and also to provide a manufacturing method thereof that can reliably cure a photocurable resin composition in a manufacturing method of an optical device in which a plurality of optical members are arranged closely to each other. [Means for solving the problem]

[0010] In order to solve the above-mentioned problems, a manufacturing method for an optical device according to the present technology is a manufacturing method for an optical device in which an optical member and a transparent panel are bonded together via a cured resin layer, the manufacturing method including the steps of: forming a wall portion on one of the optical member or the transparent panel, the wall portion surrounding a formation area of ​​the cured resin layer and having at least one opening; bonding the optical member and the transparent panel together to form a bonded body in which a resin-filled space surrounded by the wall portion is formed between the optical member and the transparent panel; filling the resin-filled space of the bonded body with a photocurable resin composition; and curing the photocurable resin composition to form the cured resin layer.

[0011] In addition, the optical device according to the present technology has an optical member, a transparent panel bonded to the optical member, and a cured resin layer filled between the optical member and the transparent panel, and the transparent panel has a light-shielding portion formed in an area corresponding to the periphery of a display area of ​​the optical member, and a wall portion defining the formation area of ​​the cured resin layer is formed on the display area side of the light-shielding portion.

[0012] In addition, the optical device according to the present technology has a plurality of optical members, a transparent panel bonded to the plurality of optical members, and a cured resin layer filled between each of the plurality of optical members and the transparent panel, and the transparent panel has a light-shielding portion formed in an area corresponding to the periphery of a display area of ​​the optical members, and a wall portion defining a filling area of ​​the cured resin layer is formed on the display area side of the light-shielding portion. Effect of the Invention

[0013] According to the present technology, a photocurable resin composition is filled into the resin filling space formed by the wall portion and then cured, eliminating the need for a large vacuum lamination device, autoclave treatment, or side cure process. [Brief description of the drawings]

[0014] [Figure 1] FIG. 1 shows a single-surface optical device, where (A) is a plan view and (B) is a cross-sectional view. [Diagram 2] FIG. 2 shows a multifaceted optical device, where (A) is a plan view and (B) is a cross-sectional view. [Diagram 3] FIG. 3 is a side view showing an example of a process for applying and curing a first curable resin composition that constitutes a wall portion to an optical member. [Figure 4] FIG. 4 is a plan view showing an optical member having a wall portion formed in a substantially frame shape. [Diagram 5] FIG. 5 is a cross-sectional view showing a bonded body in which a resin-filled space surrounded by walls is formed between an optical member and a transparent panel. [Figure 6]FIG. 6 is a side view showing a step of inserting an injection nozzle from the opening and filling the resin filling space with a curable resin composition. [Figure 7] FIG. 7 is a side view showing a process of irradiating the resin-filled space with curing light from the transparent panel side to cure the curable resin composition and form a cured resin layer. [Figure 8] FIG. 8 is a plan view showing a polygonal optical device in which one optical member and a transparent panel are laminated with a cured resin layer interposed therebetween. [Figure 9] FIG. 9 is a side view showing a bonded body in which a protrusion is formed at an opening in a wall portion so as to extend outward from a resin-filled space surrounded by the wall portion. [Figure 10] FIG. 10 is a cross-sectional view showing a state in which a wall portion is formed on the transparent panel side. [Figure 11] FIG. 11 is a side view showing a step of piercing a hollow needle through a wall portion and filling a curable resin composition into the resin filling space. [Figure 12] FIG. 12 is a side view showing a process of tilting the bonded body to fill the resin filling space with a curable resin composition, and then returning the body to a horizontal position to allow curing. [Figure 13] FIG. 13 is a side view showing a process of tilting the bonded body to fill the resin filling space with a curable resin composition, and then returning the body to a horizontal position to allow the composition to harden. [Figure 14] FIG. 14 is a cross-sectional view showing a process of bonding an optical member to a transparent panel having adjacent light-shielding portions and performing a side cure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] Hereinafter, an optical device to which the present technology is applied and a manufacturing method for an optical device will be described in detail with reference to the drawings. Note that the present technology is not limited to the following embodiments, and various modifications are possible within the scope of the present technology. In addition, the drawings are schematic, and the ratios of the dimensions may differ from the actual ones. Specific dimensions should be determined with reference to the following explanation. In addition, the drawings include parts in which the dimensional relationships and ratios differ from each other.

[0016] [Optical device 1] The present technology relates to an optical device 1 and a manufacturing method for the optical device 1, which are formed by bonding an optical member 2 and a transparent panel 4 together via a cured resin layer 3. Prior to describing the method for bonding the transparent panel 4 and the optical member 2, the configuration of the optical device 1 will be described.

[0017] The optical device 1 is a liquid crystal display panel, an organic EL display panel, or other optical device, and is used in various information terminals and information devices, such as smartphones, car navigation systems, instrument panels, etc. As shown in Figures 1(A)(B) and 2(A)(B), the optical device 1 has a light-transmitting cured resin layer 3 provided between an optical member 2, such as a liquid crystal display panel, and a transparent panel 4 that protects the optical member 2, for the purpose of making the optical device 1 thinner and improving visibility.

[0018] The optical devices 1 include a single-sided optical device 1A in which one optical member 2 and one transparent panel 4 are laminated with a cured resin layer 3 interposed therebetween, as shown in Fig. 1, and a multi-sided optical device 1B in which a plurality of optical members 2 and one transparent panel 4 are laminated with a cured resin layer 3 interposed therebetween, as shown in Fig. 2. The multi-sided optical device 1B is configured such that a plurality of optical members 2 are bonded to a transparent panel 4, and as an example, two optical members 2A and 2B are arranged side by side in Fig. 2.

[0019] [Transparent Panel 4] The transparent panel 4 has optical transparency, and is laminated on the optical member 2 via the cured resin layer 3 to cover and protect the display surface of the optical member 2 while ensuring the visibility of the optical member 2 .

[0020] The material of the transparent panel 4 may be any material that has sufficient optical transparency to allow the image formed on the optical member to be visible, and examples of such materials include glass and resin materials such as acrylic resin, polyethylene terephthalate, polyethylene naphthalate, and polycarbonate. These materials may be subjected to a hard coat treatment or an anti-reflection treatment on one or both sides. In addition, when the optical member 2 described later is a touch panel, a part of the member of the touch panel may be used as the transparent panel 4.

[0021] In addition, in order to improve the brightness and contrast of a displayed image, the transparent panel 4 has a black frame-shaped light-shielding portion 8, known as a black matrix, formed in an area corresponding to the periphery of the display area of ​​the optical member 2. In the optical device 1, the inside of the light-shielding portion 8 surrounding the display area of ​​the optical member 2 becomes a display portion 9 that transmits the display area of ​​the optical member 2 through the transparent panel 4.

[0022] The light-shielding portion 8 is formed to a uniform thickness by applying paint colored in black or the like by screen printing or the like, and then drying and hardening it. The thickness of the light-shielding portion 8 is usually 5 to 100 μm. As shown in FIG. 2, the transparent panel 4 of the polygonal optical device 1B is provided with a plurality of display portions 9 by forming frame-shaped light-shielding portions 8 in accordance with the optical members 2A and 2B.

[0023] The shape of the transparent panel 4 is not particularly limited, and may be, for example, a flat shape, a shape curved in one direction, a paraboloid of revolution, a hyperbolic paraboloid, or other quadratic surface shape, and further, the curved shape and quadratic surface shape may have a flat portion as part of the curved shape.

[0024] The dimensional characteristics of the cover member, such as the curved shape and thickness, and physical properties, such as elasticity, can be appropriately determined depending on the intended use of the optical device 1.

[0025] [Optical component 2] Examples of the optical member 2 include image display members such as a liquid crystal display panel, an organic EL display panel, a plasma display panel, and a touch panel. Here, the touch panel means an image display / input panel that combines a display element such as a liquid crystal display panel with a position input device such as a touch pad. The surface shape of the optical member 2 on the transparent panel 4 side is not particularly limited, but is preferably flat. In addition, a polarizing plate may be disposed on the surface of the optical member 2.

[0026] [Wall part 12] In the optical device 1 to which the present technology is applied, a wall portion 12 is formed on one of the bonding surfaces of the optical member 2 or the transparent panel 4, which defines a region in which a cured resin layer 3 described below is to be formed. The wall portion 12 defines a filling region of the photocurable resin composition 30 constituting the cured resin layer 3, and prevents the photocurable resin composition 30 from protruding outward from the wall portion 12. The wall portion 12 is formed in a substantially frame shape along the light shielding portion 8 on the display region side of the light shielding portion 8 which is formed in a frame shape. As a result, the wall portion 12 is provided in contact with the inside of the light shielding portion 8. The wall portion 12 may also be formed from the upper surface of the light shielding portion 8 to the display region side surrounded by the light shielding portion 8.

[0027] The wall 12 is formed on the optical member 2 or the transparent panel 4, and is preferably formed on a flat surface so as to have a substantially uniform thickness over the entire length, and is preferably formed on the optical member 2 side having a generally flat display area. The wall 12 may, of course, be formed on the transparent panel 4. The wall 12 forms a filling space filled with the photocurable resin composition 30 together with the optical member 2 and the transparent panel 4 by bonding the optical member 2 and the transparent panel 4 together. The wall 12 has elasticity and high adhesion as described later, and can prevent leakage of the filled photocurable resin composition 30 by adhering closely to the transparent panel 4 or the optical member 2 to be bonded.

[0028] Moreover, the wall portion 12 is preferably formed from the same resin composition as the cured resin layer 3 described below. The wall portion 12 is formed inside the light-shielding portion 8 and thus formed within the display portion 9 of the optical device 1 that transmits light through the display area of ​​the optical member 2, and therefore has light transparency similar to that of the cured resin layer 3. Furthermore, since the wall portion 12 contacts the cured resin layer 3 within the display portion 9, and thus is formed from the same resin composition, no interface with the cured resin layer 3 appears, and display properties are not impaired.

[0029] The height of the wall 12 can be appropriately set depending on the thickness of the cured resin layer 3 to be formed, but as an example, it is formed to a height of 50 to 100 μm in a state where it is sandwiched between the optical member 2 and the transparent panel 4. Note that the process of forming such wall 12 and the process of forming the filling space with the photocurable resin composition will be described in detail later.

[0030] [Cured resin layer] The cured resin layer 3 interposed between the transparent panel 4 and the optical member 2 has optical transparency, and allows the image displayed by the optical member 2, such as an image display member, to be visible.

[0031] The photocurable resin composition 30 constituting the cured resin layer 3 is in a liquid state, and, as one example, has a viscosity of 0.01 to 100 Pa·s (25° C.) as measured by a cone-plate viscometer.

[0032] A preferred example of such a photocurable resin composition 30 is one containing a base component (component (a)), an acrylate monomer component (component (b)), a plasticizer component (component (c)), and a photopolymerization initiator (component (d)).

[0033] <Ingredient (a)> The base component of component (A) is a film-forming component for the light-transmitting cured resin layer 3, and is a component containing at least one of an elastomer and an acrylic oligomer. Both may be used in combination as component (A).

[0034] Preferred examples of the elastomer include acrylic copolymers made of acrylic ester copolymers, polybutene, polyolefins, etc. The weight average molecular weight of the acrylic ester copolymer is preferably 5,000 to 500,000, and the repeat number n of polybutene is preferably 10 to 10,000.

[0035] On the other hand, the acrylic oligomer preferably includes a (meth)acrylate oligomer having a skeleton of polyisoprene, polyurethane, polybutadiene, etc. In this specification, the term "(meth)acrylate" includes acrylate and methacrylate.

[0036] Preferred specific examples of the (meth)acrylate oligomer having a polyisoprene skeleton include an ester of a maleic anhydride adduct of a polyisoprene polymer and 2-hydroxyethyl methacrylate (UC102 (polystyrene-equivalent molecular weight: 17,000), Kuraray Co., Ltd.; UC203 (polystyrene-equivalent molecular weight: 35,000), Kuraray Co., Ltd.; UC-1 (molecular weight: approximately 25,000), Kuraray Co., Ltd.).

[0037] In addition, preferred specific examples of the (meth)acrylic oligomer having a polyurethane skeleton include aliphatic urethane acrylate (EBECRYL230 (molecular weight 5000), Daicel-Cytec Co., Ltd.; UA-1, Light Chemical Co., Ltd.).

[0038] As the (meth)acrylate oligomer having a polybutadiene skeleton, known ones can be used.

[0039] <Ingredients (b)> The acrylic monomer component of component (b) is used as a reactive diluent in the manufacturing process of an optical device to impart sufficient reactivity and coatability to the photocurable resin composition. Examples of such acrylic monomers include 2-hydroxypropyl methacrylate, benzyl acrylate, and dicyclopentenyloxyethyl methacrylate.

[0040] The total content of the base component (a) and the acrylic monomer component (b) in the photocurable resin composition 30 is preferably 25 to 85% by mass.

[0041] <Ingredients (H)> The plasticizer component (c) is used to impart cushioning properties to the cured resin layer and to reduce the cure shrinkage rate of the photocurable resin composition, and does not react with the acrylate oligomer component (a) and the acrylate monomer component (b) when irradiated with ultraviolet light. Such a plasticizer component contains a solid tackifier (1) and a liquid oil component (2).

[0042] Examples of the solid tackifier (1) include terpene resins such as terpene resins, terpene phenol resins, and hydrogenated terpene resins, rosin resins such as natural rosin, polymerized rosin, rosin ester, and hydrogenated rosin, and hydrogenated terpene resins. In addition, non-reactive oligomers obtained by previously polymerizing the above-mentioned acrylate monomers into low molecular weight polymers can also be used, and specific examples include copolymers of butyl acrylate, 2-hexyl acrylate, and acrylic acid, and copolymers of cyclohexyl acrylate and methacrylic acid.

[0043] The liquid oil component (2) may contain polybutadiene-based oil, polyisoprene-based oil, or the like.

[0044] The content of the plasticizer component, component (iii), in the photocurable resin composition 30 is preferably 10 to 65% by mass.

[0045] <Ingredients (D)> As the photopolymerization initiator of component (iv), a known photoradical polymerization initiator can be used, such as 1-hydroxycyclohexylphenyl ketone (Irgacure 184, BASF), 2-hydroxy-1-{4-[4-(2-hydroxy-2-methyl-propylonyl)benzyl]phenyl}-2-methyl-1-propan-1-one (Irgacure 127, BASF), benzophenone, acetophenone, and the like.

[0046] The amount of such photopolymerization initiator, relative to 100 parts by mass of the total of the base component (a) and the acrylic monomer component (b), is preferably 0.1 to 5 parts by mass, and more preferably 0.2 to 3 parts by mass, since too little will result in insufficient curing upon irradiation with ultraviolet light, and too much will tend to increase outgassing due to cleavage and cause foaming, resulting in problems.

[0047] The photocurable resin composition 30 may contain a chain transfer agent to adjust the molecular weight, such as 2-mercaptoethanol, lauryl mercaptan, glycidyl mercaptan, mercaptoacetic acid, 2-ethylhexyl thioglycolate, 2,3-dimethylcapto-1-propanol, and α-methylstyrene dimer.

[0048] Furthermore, the photocurable resin composition 30 may further contain, as necessary, general additives such as an adhesion improver such as a silane coupling agent, an antioxidant, etc. Regarding the components (A) to (D) of the photocurable resin composition, if components (B) and (C) are devised, it is not necessary to use component (A). [Manufacturing process]

[0049] [First manufacturing process] Next, the first manufacturing process of the optical device 1 will be described with reference to a manufacturing method of the multi-faceted optical device 1B shown in Fig. 2. The first manufacturing process of the optical device 1 includes a step (A) of forming a wall 12 made of a first curable resin composition 31 on one of the optical member 2 or the transparent panel 4, the wall 12 surrounding the region where the cured resin layer 3 is formed and having at least one opening 13, a step (B) of bonding the optical member 2 and the transparent panel 4 to form a bonded body 10 in which a resin-filled space 14 surrounded by the wall 12 is formed between the optical member 2 and the transparent panel 4, a step (C) of filling the photocurable resin composition 30 from the opening 13 of the bonded body 10, and a step (D) of curing the photocurable resin composition 30 to form the cured resin layer 3.

[0050] [Process A] First, prepare two optical members 2 and one transparent panel 4. As described above, the transparent panel 4 has a light-shielding portion 8 formed on one surface to which the optical members 2 are attached. The light-shielding portion 8 is formed so as to surround each display region of the two adjacent optical members 2 that are attached to each other, and has the shape of two rectangular frames that share one side.

[0051] Further, in each optical member 2, a wall portion 12 made of a first curable resin composition 31 is formed, which surrounds the region where the cured resin layer 3 is formed and has at least one opening 13 provided therein.

[0052] The wall portion 12 is formed by applying and curing a first curable resin composition 31 in a predetermined shape as shown in Fig. 3. The wall portion 12 is formed so as to abut from the upper surface to the inside of the light-shielding portion 8 when it is attached to the transparent panel 4, and is formed in a substantially frame shape according to the light-shielding portion 8 that is formed in a frame shape as shown in Fig. 4, for example.

[0053] The first curable resin composition 31 is applied in a substantially frame-like shape by a dispenser, for example, as shown in Fig. 3. When a photocurable resin composition is used as the first curable resin composition 31, the composition is irradiated with curing light after application and cured. Alternatively, the first curable resin composition 31 may be applied by a known resin supplying method such as printing.

[0054] The cured wall 12 has elasticity and high adhesion, and when it is pressed against the transparent panel 4 later, it is crushed into a substantially trapezoidal cross section, and bulges toward the upper surface of the light-shielding portion 8 of the transparent panel 4 and the display area side of the optical member 2 while being tightly adhered to the transparent panel 4. As a result, the wall 12 forms a resin-filled space 14 between the optical member 2 and the transparent panel 4 into which the photocurable resin composition 30 is filled, and prevents leakage of the photocurable resin composition 30. The application height of the first curable resin composition 31 is determined by the thickness of the laminate with the transparent panel 4, plus the bulge caused by the wall 12 being crushed toward the upper surface of the light-shielding portion 8 and the display area side of the optical member 2.

[0055] Here, as shown in FIG. 4, the wall 12 formed in a substantially frame shape is provided with at least one opening 13. The opening 13 is an injection hole for injecting the photocurable resin composition 30 into the resin filling space 14, and also an exhaust hole for exhausting the air in the resin filling space 14. The opening 13 has an opening diameter that allows an injection nozzle 17 (see FIG. 6) for injecting the photocurable resin composition 30 to be inserted and allows the air in the resin filling space 14 to be exhausted. The opening 13 may be formed anywhere on the wall 12, but by forming the opening 13 near a corner, the photocurable resin composition 30 can be injected with the opening 13 facing upward, and exhaust of the air in the resin filling space 14 can be prevented from being hindered by the wall 12, so that the photocurable resin composition 30 can be reliably filled into the resin filling space 14.

[0056] [Process B] Next, as shown in Fig. 5, the optical member 2 and the transparent panel 4 are bonded together to form a bonded body 10 in which a resin-filled space 14 surrounded by a wall portion 12 is formed between the optical member 2 and the transparent panel 4. Fig. 5 is a top cross-sectional view of the bonded body 10. The transparent panel 4 and the optical member 2 are supported by a fixing plate 16 provided on the back surface opposite to the bonding surface. The bonded body 10 is formed by arranging the transparent panel 4 and the optical member 2 so that the light-shielding portion 8 formed in a frame shape faces the wall portion 12, and sandwiching them with the fixing plate 16.

[0057] As described above, the wall portion 12 has elasticity and high adhesion, and when pressed against the transparent panel 4 via the fixing plate 16, it is crushed into a substantially trapezoidal cross section and adheres closely to the upper surface and inner side of the light-shielding portion 8 of the transparent panel 4. As a result, in the laminate 10, a resin-filled space 14 is formed by the optical member 2, the transparent panel 4, and the wall portion 12 into which the photocurable resin composition 30 is filled, and the resin-filled space 14 is capable of being injected with the photocurable resin composition 30 from an opening 13 provided in the wall portion 12. In addition, the wall portion 12 adheres closely to the transparent panel 4, so that the resin-filled space 14 prevents leakage of the photocurable resin composition 30.

[0058] [Process C] 6, an injection nozzle 17 is inserted from the opening 13 of the resin filling space 14, and the resin filling space 14 is filled with a photocurable resin composition 30. At this time, by filling the photocurable resin composition 30 with the opening 13 facing upward, the air in the resin filling space 14 can be exhausted from the opening 13, and the occurrence of voids can be prevented.

[0059] 6, the step of filling the photocurable resin composition 30 is preferably performed by tilting the laminate 10 so that the opening 13 is located at the top in the vertical direction. This prevents air in the resin filling space 14 from flowing to the opening 13 side and remaining as voids in the corners of the resin filling space 14.

[0060] The injection nozzle 17 can fill the photocurable resin composition 30 as long as the tip is inserted into the opening 13, but by immersing the tip into the photocurable resin composition 30 filled in the resin filling space 14, it is possible to fill the resin composition quickly while preventing air from being entrained.

[0061] [Process D] After the filling of the photocurable resin composition 30 is completed, the injection nozzle 17 is withdrawn from the resin filling space 14 .

[0062] 7, curing light such as ultraviolet light is irradiated from the transparent panel 4 side to the resin filled space 14 to cure the photocurable resin composition 30 and form a cured resin layer 3. In addition, curing light is irradiated from the side surface of the bonded body 10 toward the opening 13, so that the opening 13 is closed by the cured resin layer 3.

[0063] As a result, one optical member 2 of the multi-faceted optical device 1B is laminated to the transparent panel 4 via the cured resin layer 3, as shown in Fig. 8. The other optical member 2 is also laminated to the transparent panel 4 via the cured resin layer 3 by a similar process, to obtain the multi-faceted optical device 1B (Fig. 2). The single-faceted optical device 1A can also be manufactured by a similar process. The photocurable resin composition 30 may be irradiated with curing light multiple times, as necessary.

[0064] In such a multi-faceted optical device 1B, the display area side of the light-shielding portion 8 is a display section 9 that transmits the display area of ​​the optical member 2, and the display section 9 is formed with a light-transmitting wall section 12 and a cured resin layer 3. In addition, since the wall section 12 and the cured resin layer 3 are formed of the same resin composition, the display section 9 does not have an interface with the cured resin layer 3, and display properties and visibility are not impaired. This is the same in the single-faced optical device 1A.

[0065] Moreover, in the multifaceted optical device 1B, the wall portion 12 is formed in contact with the light-shielding portion 8, and the resin-filled space 14 surrounded by the wall portion 12 is filled with the photocurable resin composition 30. That is, the resin-filled space 14 filled with the photocurable resin composition 30 appears on the transparent panel 4 side, and no blind spots are generated. Therefore, even when the display unit 9 is disposed closely sharing one side of the light-shielding portion 8, the photocurable resin composition 30 in the resin-filled space 14 can be irradiated with curing light through the transparent panel 4, and the occurrence of uncured portions can be prevented.

[0066] In the multifaceted optical device 1B, a laminate 10 may be formed by simultaneously laminating a plurality of optical members 2, each having a wall portion 12, to a transparent panel 4. In addition, in the multifaceted optical device 1B, a photocurable resin composition 30 may be simultaneously filled and cured in each resin-filled space 14 of the laminate 10, in which a plurality of optical members 2 are laminated together. This can shorten the manufacturing time.

[0067] [Variation 1] 9, the manufacturing method of the optical device to which the present technology is applied may form a protrusion 13a at the opening 13 of the wall portion 12, the protrusion 13a extending out to the outside of the resin-filled space 14 surrounded by the wall portion 12. By filling the photocurable resin composition 30 up to the protrusion 13a, the photocurable resin composition 30 can be sufficiently spread throughout the entire resin-filled space 14 surrounded by the wall portion 12.

[0068] [Variation 2] In the above, the wall portion 12 is formed on the optical member 2 side, but in the manufacturing method of the optical device to which the present technology is applied, the wall portion 12 may be formed on the transparent panel 4 side as shown in Fig. 10. In this case, it is preferable that the transparent panel 4 is formed flat in order to form the wall portion 12 at a uniform height over its entire length.

[0069] [Variation 3] In the above, the injection nozzle 17 is inserted into the opening 13 to fill the photocurable resin composition 30, but the manufacturing method of the optical device to which the present technology is applied may be such that, as shown in FIG. 11, a hollow needle 18 is inserted into the elastic wall 12 and the photocurable resin composition 30 is filled into the resin filling space 14 through the hollow needle 18. The hollow needle 18 has a sharp tip like an injection needle, and pierces the wall 12 and injects the photocurable resin composition 30 from the tip inserted into the resin filling space 14. The wall 12 is elastic and adhesive, so it adheres closely to the hollow needle 18, and the photocurable resin composition 30 does not leak out from the hole of the hollow needle 18. In addition, as the photocurable resin composition 30 is filled, the air in the resin filling space 14 is exhausted from the opening 13.

[0070] This allows the opening diameter of the opening 13 to be kept to the minimum diameter necessary for exhaust, and prevents leakage of the photocurable resin composition 30 from the opening 13. Also, the tip of the hollow needle 18 can be immersed in the photocurable resin composition 30 filled in the resin filling space 14 when injection is performed, allowing high-speed filling while preventing air from getting mixed in.

[0071] The position where the hollow needle 18 is inserted may be anywhere on the wall 12. However, it is preferable to insert the hollow needle 18 into the lower part of the resin filling space 14 on the side opposite the opening 13, as shown in FIG. 11, in order to inject the photocurable resin composition 30 filled in the resin filling space 14 while immersing the tip of the hollow needle 18 in the photocurable resin composition 30.

[0072] In addition, it is preferable that the thickness of the wall portion 12 at the portion where the hollow needle 18 is pierced is relatively thicker than other portions. This can better prevent leakage of the photocurable resin composition 30 from the hole of the hollow needle 18.

[0073] [Variation 4] Furthermore, in the manufacturing method of an optical device to which the present technology is applied, the step of filling the resin filling space 14 with the photocurable resin composition 30 and the step of curing the photocurable resin composition 30 filled in the resin filling space 14 may be performed in parallel. That is, while filling the resin filling space 14 with the photocurable resin composition 30, the photocurable resin composition 30 filled in the resin filling space 14 may be irradiated with curing light to sequentially progress the curing reaction.

[0074] By sequentially curing the photocurable resin composition 30 before it fills the entire resin filling space 14, it is possible to suppress an increase in internal pressure caused by the uncured photocurable resin composition 30 filling the resin filling space 14, thereby reducing the load on the transparent panel 4 and optical component 2, which are becoming thinner, and enabling the cured resin layer 3 to be formed to a uniform thickness.

[0075] Furthermore, the manufacturing time can be reduced by carrying out the step of filling the photocurable resin composition 30 and the step of curing in parallel.

[0076] [Variation 5] Furthermore, in the manufacturing method of an optical device to which the present technology is applied, in the step of filling the resin filling space 14 with the photocurable resin composition 30, the air in the resin filling space 14 may be sucked through the opening 13 to reduce the pressure. This makes it possible to prevent air from being mixed into the photocurable resin composition 30 filled in the resin filling space 14, and also makes it possible to fill the resin filling space 14 with the photocurable resin composition 30 at high speed, thereby shortening the filling time.

[0077] [Variation 6] Furthermore, in the manufacturing method of an optical device to which the present technology is applied, two openings 13 may be provided: an injection hole for injecting the photocurable resin composition 30, and an exhaust hole for exhausting air from within the resin filling space 14. The injection hole and the exhaust hole may be provided close to each other or may be provided apart from each other, but it is required that they are both formed at positions where they can face vertically upward in the step of filling the photocurable resin composition 30.

[0078] [Variation 7] In addition, in the manufacturing method of the optical device to which the present technology is applied, when the bonded body 10 is tilted so that the opening 13 is located at the top as shown in Fig. 7 and the photocurable resin composition 30 is filled, the bonded body 10 may be returned to the horizontal position when the curing light is irradiated to the resin-filled space 14 as shown in Fig. 12. This makes it possible to prevent an unfilled portion of the photocurable resin composition 30 from occurring near the opening 13 of the resin-filled space 14 due to the inclination of the bonded body 10. Therefore, the photocurable resin composition 30 is filled up to the opening 13, and the curing light can be irradiated in a state in which the photocurable resin composition 30 is filled in the entire display area.

[0079] Similarly, even in a configuration in which a protrusion 13a is formed at the opening 13 as shown in FIG. 9, if the laminated body 10 is tilted so that the opening 13 is positioned at the top and the photocurable resin composition 30 is filled, the laminated body 10 may be returned to a horizontal position when the curing light is irradiated to the resin filling space 14 as shown in FIG. 13. EXAMPLES

[0080] Next, an example of forming a multi-faceted optical device using this technology will be described. In this example, a cover glass is prepared as the transparent panel 4, and two liquid crystal displays (LCDs) are prepared as the optical members 2, and the multi-faceted optical device is formed by bonding each liquid crystal display to the cover glass via an ultraviolet-curable cured resin layer. A black frame-shaped light-shielding portion is formed on the cover glass at a position corresponding to the periphery of the display area of ​​each LCD.

[0081] First, the liquid crystal display was placed on the table of the dispenser coating device. Next, an optical elastic resin (product name CA201; manufactured by Dexerials Corporation) with a viscosity of 50000 mPa·S was set in an injection nozzle (manufactured by Musashi Engineering Co., Ltd.) as a photocurable resin composition for forming the wall portion 12.

[0082] Next, the optical elastic resin was applied to the display surface of the LCD under the following conditions: gap between the injection nozzle and the LCD: 0.9 mm, dispensing pressure: 0.5 MPa, and application speed: 30 mm / sec. At this time, the optical elastic resin was applied in a substantially frame-like shape corresponding to the light-shielding portion, and was applied in a position offset 0.5 mm outward from the opening of the frame-like light-shielding portion formed in the cover glass. Also, the optical elastic resin was provided with a non-applied portion that formed an opening in a part of it.

[0083] The optical elastic resin is immediately exposed to ultraviolet light (4000 mJ / cm 2 ) is irradiated and cured. This forms a wall having a height of about 0.7 mm and a width of about 2.0 mm.

[0084] Next, the cover glass was fixed vertically with a fixing plate, and the back side of the LCD with the wall formed on the display side was fixed to the fixing plate. The cover glass and the LCD were aligned and bonded together with a gap of 0.5 mm to form a bonded body with a resin-filled space. The cover glass and the LCD were then pressed together to crush the wall to a height of about 0.2 mm. This allowed the wall to absorb the unevenness of the upper surface, adhere to the cover glass and the LCD, and bulge 1 mm from the upper surface of the light-shielding part toward the display area.

[0085] Next, an injection nozzle was inserted through the opening, and the photocurable resin composition that constitutes the cured resin layer was filled into the resin filling space. The photocurable resin composition used was product name: 18V028, manufactured by Dexerials Corporation, viscosity: 20 mPa·S. A #22 70 cc syringe manufactured by Musashi Engineering was used as the injection nozzle.

[0086] The filling step was performed in a state where the laminate was stood so that the surface direction was vertical and tilted so that the opening was at the highest position. The filling step was completed when the photocurable resin composition was filled up to the opening.

[0087] Next, a predetermined amount of ultraviolet light (2000 mJ / cm ) was applied to the bonded body from the cover glass side. 2 ) was irradiated toward the opening to cure the photocurable resin composition. 2 ) was irradiated to cure the photocurable resin composition filled in the opening. This resulted in an optical device in which the cover glass and the LCD were bonded together via the cured resin layer. The fixing member on the LCD side was then released. The above-mentioned process was repeated to obtain a multifaceted optical device.

[0088] The obtained polygonal optical device had no leakage of the photocurable resin composition and no problems with the bonding strength between the cover glass and the LCD, and it was confirmed that the wall portion on the upper surface of the light-shielding portion had also progressed in hardening. [Explanation of symbols]

[0089] REFERENCE SIGNS LIST 1 Optical device, 1A Single-sided optical device, 1B Multi-sided optical device, 2 Optical member, 3 Cured resin layer, 4 Transparent panel, 8 Light-shielding portion, 9 Display portion, 10 Bonded body, 12 Wall portion, 13 Opening portion, 14 Resin-filled space, 16 Fixing plate, 17 Injection nozzle, 18 Hollow needle, 30 Photocurable resin composition, 31 First cured resin composition

Claims

1. A method for manufacturing an optical device in which an optical member and a transparent panel are bonded together via a cured resin layer, comprising the steps of: forming a wall portion on one of the optical member or the transparent panel, the wall portion surrounding a region where the cured resin layer is formed and having at least one opening; a step of bonding the optical member and the transparent panel together to form a bonded body in which a resin-filled space surrounded by the wall portion is formed between the optical member and the transparent panel; filling the resin filling space of the laminate with a photocurable resin composition; and curing the photocurable resin composition to form the cured resin layer. The photocurable resin composition has a viscosity of 0.01 to 100 Pa·s (25° C.) as measured by a cone-plate viscometer, a protrusion extending outward from a resin filling space surrounded by the wall portion is formed at an opening of the wall portion, In the step of filling the photocurable resin composition, the laminate is tilted so that the opening is positioned at the top in the vertical direction, and the photocurable resin composition is filled. A method for manufacturing an optical device.

2. 2. The method for manufacturing an optical device according to claim 1, wherein the photocurable resin composition is filled into the resin filling space by piercing a hollow needle through the wall portion.

3. The method for manufacturing an optical device according to claim 2 , wherein the wall portion is formed so that the portion pierced by the hollow needle is thicker than other portions.

4. The method for manufacturing an optical device according to any one of claims 1 to 3, wherein in the step of filling the photocurable resin composition, the resin filling space is depressurized by sucking in the air therein through the opening.

5. The method for manufacturing an optical device according to any one of claims 1 to 4, wherein a step of filling the resin filling space with the photocurable resin composition and a step of curing the photocurable resin composition filled in the resin filling space are carried out in parallel.

6. 2. The method for manufacturing an optical device according to claim 1, wherein the opening is provided in two places: an injection hole for injecting the photocurable resin composition, and an exhaust hole for exhausting air from within the resin-filled space.

7. 2. The method for manufacturing an optical device according to claim 1, wherein the bonded body is returned to a horizontal position and the photocurable resin composition is cured to form the cured resin layer.

8. the transparent panel has a light-shielding portion formed in a region corresponding to a periphery of a display region of the optical member; The method for manufacturing an optical device according to any one of claims 1 to 7, wherein the wall portion is provided on a side of the light blocking portion that surrounds a display area of ​​the optical member, the side of the light blocking portion being on the side of the display area.

9. The method for manufacturing an optical device according to claim 8 , wherein the wall portion is provided from an upper surface of the light blocking portion to a side of the display area.

10. 10. The method for manufacturing an optical device according to claim 1, wherein the wall portion and the cured resin layer are made of the same photocurable resin composition.

11. A method for manufacturing an optical device in which an optical member and a transparent panel are bonded together via a cured resin layer, comprising the steps of: forming a wall portion on one of the optical member or the transparent panel, the wall portion surrounding a region where the cured resin layer is formed and having at least one opening; a step of bonding the optical member and the transparent panel together to form a bonded body in which a resin-filled space surrounded by the wall portion is formed between the optical member and the transparent panel; filling the resin filling space of the laminate with a photocurable resin composition; and curing the photocurable resin composition to form the cured resin layer. The photocurable resin composition has a viscosity of 0.01 to 100 Pa·s (25° C.) as measured by a cone-plate viscometer, In the step of filling the photocurable resin composition, the laminate is tilted so that the opening is positioned at the top in the vertical direction, and the photocurable resin composition is filled; In the step of curing the photocurable resin composition to form the cured resin layer, the laminate filled with the photocurable resin composition is returned to a horizontal position to cure the photocurable resin composition. A method for manufacturing an optical device.

12. The method for manufacturing an optical device according to claim 11 , wherein in the step of curing the photocurable resin composition to form the cured resin layer, the photocurable resin composition is cured by irradiating it with curing light.

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