Complex three-dimensional multi-layer structure and manufacturing method thereof

Abstract

The present invention relates to a 3-dimensional complex multilayer structure. The 3-dimensional complex multilayer structure includes a first pattern and a second pattern having different thicknesses formed on one or both surfaces of a plate. The first pattern is selected from the group consisting of parallel lines, parallel curves, parallel zigzag lines, and combinations thereof which do not meet each other. The second pattern is not parallel to the first pattern and is selected from the group consisting of parallel lines, parallel curves, parallel zigzag lines, and combinations thereof which do not meet each other. The interfaces between the first pattern and the second pattern form figures selected from the group consisting of polygons, circles, ellipses, and combinations thereof. The figures are repetitively formed on one or both surfaces of the plate. The 3-dimensional complex multilayer structure includes different complex patterns, whereas a conventional device has a kind of simple pattern. The 3-dimensional complex multilayer structure of the present invention can be manufactured by a simple process. Therefore, the 3-dimensional complex multilayer structure of the present invention can find application in various fields, including optical components for displays (e.g., light guide plates, diffusion plates, prisms, and color filters), next generation displays and display devices (e.g., TFTs, OTFTs, oxide TFTs, flexible displays, and transparent displays), next generation 3-dimensional semiconductors, dry adhesion based on the use of fine ciliary structures, micro/nano piezoelectric devices, lighting optical components, and biocell/virus research using micropatterns.

Claims

1. A method for manufacturing a 3-dimensional complex multilayer structure, comprising: (A) preparing a second base mold having a first pattern selected from the group consisting of parallel lines, parallel curves, parallel zigzag lines, and combinations thereof which do not meet each other, on one surface thereof; (B) preparing a mask mold comprising a first support in the form of a flexible or rigid plate through which active energy rays transmit, a mask repetitively formed or perforated with polygons, circles, ellipses or combinations thereof on one surface of the first support and through which active energy rays do not transmit, and a patterned layer adapted to cover the first support and the mask and having a second pattern formed on the surface opposite to the surface facing the first support or a second pattern formed in an exposed portion of one surface of the first support; (C) applying a resin for a second mold onto the first pattern of the second base mold or the mask mold; (D) pressing the second base mold against the mask mold, which is separated from the second base mold by the resin, to the extent that a third pattern is formed through which the first and second patterns are spaced a predetermined height T from each other and such that the parallel direction of the second pattern is not parallel to that of the first pattern; (E) pressurizing the mask mold toward the resin and curing the resin by irradiating the mask mold with active energy rays or heating the mask mold to form a second mold; (F) separating the second mold and the mask mold from each other; and (G) removing an uncured portion of the resin by dissolution in a solvent to develop the third pattern.

2. The method according to claim 1, further comprising (H) applying a resin for a third mold to the multilayer structure having undergone step (G) as a master, (I) bringing a second support into close contact with the resin, (J) pressurizing the second support toward the master and curing the resin by irradiating the second support with active energy rays or heating the second support to form a third mold, (K) separating the third mold from the master, (L) applying a resin for patterning to the third mold or a substrate, (M) pressing the third mold against the substrate, which is separated from the third mold by the resin for patterning, (N) curing the resin by irradiating the third support or the substrate with active energy rays or heating the third support or the substrate to form a pattern, and (0) separating the patterned 3-dimensional complex multilayer structure from the third mold.

3. The method according to claim 1, wherein the second pattern is not parallel to the first pattern and is selected from the group consisting of parallel lines, parallel curves, parallel zigzag lines, and combinations thereof which do not meet each other.

4. The method according to claim 2, wherein the second pattern is not parallel to the first pattern and is selected from the group consisting of parallel lines, parallel curves, parallel zigzag lines, and combinations thereof which do not meet each other.

5. The method according to claim 1, wherein the parallel direction of the second pattern is orthogonal to the parallel direction of the first pattern.

6. The method of claim 1 wherein the first pattern has a height H1 and the second pattern has a height H2, and the height T of the third pattern is equal to or higher than the height H1 of the first pattern (T> H1) or the height H2 of the second pattern (T> H2).

7. The method according to claim 1, wherein the third pattern comprises figures formed at interfaces along the plane of the surface between the first pattern and the second pattern wherein the figures comprise spatially separated figures surrounding regions of the second pattern.

8. The method according to claim 7 further comprising selecting the figures from the group consisting of polygons, circles, ellipses, and combinations thereof.

9. The method according to claim 7, wherein the figures are repetitively formed on one or both surfaces of the plate.

10. The method according to claim 1, wherein the first pattern extends across the plane of the surface surrounding the second pattern.

11. The method of claim 1 further comprising forming an adhesion promoting layer between the patterned layer and the first support and/or between the patterned layer and the mask.

12. The method according to claim 1, wherein a cross section perpendicular to the parallel directions of the first and second patterns is in the form of a wave, and a pair of adjacent troughs and a crest between the troughs correspond to the three corners of a triangle, both end points of a chord and one point of an arc of a segment of a circle, both end points of a chord and one point of an arc of a segment of an ellipse, or the two corners and one round-edged corner of a triangle in the wavy cross section.

13. The method of claim 12, wherein the height from the trough to the crest in the wavy cross section is from 1 to 500 m.

14. The method of claim 9, wherein the diameter, the longest diameter or the length of one of the sides of each of the repetitively formed figures is from 1 to 5000 m.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view illustrating one embodiment of the present invention in which a first pattern is a prism pattern and a second pattern is a prism pattern orthogonal to the parallel direction of the first pattern;

(2) FIG. 2 is a partially enlarged view of FIG. 1;

(3) FIG. 3 is a plan view illustrating one embodiment of the present invention in which a first pattern of parallel curves is combined with a second pattern of parallel curves orthogonal to the parallel direction of the first pattern;

(4) FIG. 4 is a plan view illustrating one embodiment of the present invention in which a first pattern of parallel curves is combined with a second pattern of parallel lines orthogonal to the parallel direction of the first pattern;

(5) FIG. 5 is a plan view illustrating one embodiment of the present invention in which a first pattern of parallel zigzag lines is combined with a second pattern of parallel zigzag lines orthogonal to the parallel direction of the first pattern;

(6) FIG. 6 is a plan view illustrating one embodiment of the present invention in which a first pattern of parallel zigzag lines is combined with a second pattern of parallel lines orthogonal to the parallel direction of the first pattern;

(7) FIG. 7 is a plan view illustrating one embodiment of the present invention in which a first pattern of parallel curves is combined with a second pattern of parallel zigzag lines and parallel lines orthogonal to the parallel direction of the first pattern;

(8) FIG. 8 is a cross-sectional view illustrating one embodiment of the present invention in which a pair of adjacent troughs and a crest between the troughs correspond to the three corners of a triangle in a wavy cross section of patterns;

(9) FIG. 9 is a cross-sectional view illustrating one embodiment of the present invention in which the crests are round-edged in FIG. 8;

(10) FIG. 10 is a cross-sectional view illustrating one embodiment of the present invention in which a pair of adjacent troughs and a crest between the troughs correspond to both end points of a chord and one point of an arc of a segment of a circle, respectively, in a wavy cross section of patterns;

(11) FIG. 11 is a cross-sectional view illustrating one embodiment of the present invention in which a pair of adjacent troughs and a crest between the troughs correspond to both end points of a chord and one point of an arc of a segment of an ellipse, respectively, in a wavy cross section of patterns;

(12) FIGS. 12 and 13 are conceptual views illustrating procedures for producing mask molds used in the manufacture of a 3-dimensional complex multilayer structure according to the present invention;

(13) FIGS. 14 and 15 are conceptual views illustrating methods for manufacturing 3-dimensional complex multilayer structures, as masters, according to embodiments of the present invention;

(14) FIG. 16 is a conceptual view illustrating a method for manufacturing a 3-dimensional complex multilayer structure from a master according to one embodiment of the present invention;

(15) FIG. 17 is an image showing one embodiment of the present invention in which a first pattern is a prism pattern and a second pattern is a prism pattern orthogonal to the parallel direction of the first pattern;

(16) FIG. 18 is a partially enlarged view of FIG. 17;

(17) FIGS. 19 to 22 are diagrams showing the results of analysis of viewing angles for a conventional light guide plate (FIG. 19), a combination of a diffusion plate with the light guide plate (FIG. 20), a combination of a diffusion plate and a first light collecting sheet with the light guide plate (FIG. 21), and a combination of a diffusion plate, a first light collecting sheet, and a second light collecting sheet with the light guide plate (FIG. 22);

(18) FIGS. 23 and 24 are diagrams showing the results of analysis of viewing angles for a 3-dimensional complex multilayer structure of the present invention as a light guide plate (FIG. 23) and a combination of a diffusion plate with the light guide plate (FIG. 24);

(19) FIG. 25 is a diagram showing the results of analysis of viewing angles for a combination of a diffusion plate with a conventional light guide plate;

(20) FIG. 26 is a diagram showing the results of analysis of viewing angles for a combination of a diffusion plate, a first light collecting sheet, and a second light collecting sheet with a conventional light guide plate; and

(21) FIG. 27 is a diagram showing the results of analysis of viewing angles for a combination of a 3-dimensional complex multilayer structure of the present invention as an optical sheet with the combination of FIG. 25.

(22) FIG. 28 is a diagram showing embodiments with a First Type, Second Type, and Third Type of structure.

(23) FIG. 29 is a diagram contrasting two structures.

DETAILED DESCRIPTION OF THE INVENTION

(24) Preferred embodiments will now be described in detail. Although explanatory description is provided with particular features such as specific elements, it is provided to assist in a more inclusive understanding of the invention and those skilled in the art will appreciate that the invention may be practiced otherwise than as specifically described herein. In the description of the present invention, detailed explanations of well-known functions or constructions are omitted when it is deemed that they may unnecessarily obscure the essence of the present invention.

(25) First, some of the terms used herein are defined.

(26) In the present specification, when structures having different pattern shapes are formed with different heights from a substrate, they are regarded as separate layers. Accordingly, a structure including all layers is referred to as a multilayer.

(27) For example, referring to the cross sections of 3-dimensional complex multilayer structures illustrated in FIGS. 14 to 16, when a pattern having a height H1 on a first base mold is defined as a first pattern and a pattern with a height H2 non-parallel to the first pattern and spaced a height T from the first pattern is defined as a second pattern, the height T can be expressed as the thickness of the second pattern or the height of a third pattern because when the heights of the second and third patterns are large, the respective structures have functions of their own.

(28) According to a first type, the height T of the third pattern may be equal to or smaller than the height H1 of the first pattern (TH1) and the height H2 of the second pattern (TH2). In the case where the height (T) of the third pattern approaches zero, the second pattern can be considered to be formed directly on the first pattern, like patterns illustrated in FIG. 18.

(29) According to a second type shown in FIG. 28, the third pattern is higher than the first and second patterns (T> H1, T> H2). The total height of the patterns is an important factor in the determination of an effective elastic modulus. In the case of a third type in which T is much higher (H2<H1<<T), the total height (H1+T+H2) is determined by T, and therefore, the third pattern performs its structural (or optical) functions.

(30) Herein, a complex optical component using a 3-dimensional complex multilayer structure of the present invention is defined as an optical member that focuses rays of light from two directions onto a direction perpendicular thereto and is intended to include optical sheets, light guide plates for edge type LCDs, diffusion plates for direct type LCDs, and light collecting sheets and light collecting plates for solar power generation devices.

(31) The term active energy rays refers to both particle beams and electromagnetic waves whose energy is sufficient to cure a given resin and is intended to include UV light, lasers, microwaves, electron beams, and X-ray.

EMBODIMENTS

(32) Hereinafter, a description will be given concerning embodiments of the present invention.

(33) The present invention provides a 3-dimensional complex multilayer structure including a first pattern, a second pattern, and optionally a third pattern wherein the first and second patterns are formed on one surface of a plate and have different thicknesses, the first pattern is selected from the group consisting of parallel lines, parallel curves, parallel zigzag lines, and combinations thereof which do not meet each other, the second pattern is not parallel to the first pattern and is selected from the group consisting of parallel lines, parallel curves, parallel zigzag lines, and combinations thereof which do not meet each other, the interfaces between the first pattern and the second pattern form figures selected from the group consisting of polygons, circles, ellipses, and combinations thereof, and the figures are repetitively formed on one surface of the plate.

(34) The two or more patterns are formed in the same plane of the 3-dimensional complex multilayer structure. This arrangement enables the 3-dimensional complex multilayer structure to perform the functions of two or more optical components. For example, the 3-dimensional complex multilayer structure of the present invention may include prism patterns as the first and second patterns. In this case, an optical sheet using the 3-dimensional complex multilayer structure can effectively collect rays of light from two directions. Alternatively, the first pattern may be a prism pattern and the second pattern may be a diffusion pattern. In this case, the 3-dimensional complex multilayer structure can perform the functions of both a light collecting sheet and a diffusion sheet.

(35) Particularly, when the parallel direction (Direction 1 in FIG. 1) of the first pattern selected from the group consisting of parallel lines, parallel curves, parallel zigzag lines, and combinations thereof which do not meet each other is orthogonal to the parallel direction (Direction 2 in FIG. 1) of the second pattern non-parallel to the first pattern and selected from the group consisting of parallel lines, parallel curves, parallel zigzag lines, and combinations thereof which do not meet each other, the 3-dimensional complex multilayer structure can effectively collect light in a direction orthogonal to each other. Accordingly, the use of the 3-dimensional complex multilayer structure in an optical component ensures a maximum luminance of the optical component.

(36) FIGS. 1 and 2 illustrate one embodiment of the present invention in which the first and second patterns are prism patterns orthogonal to each other. The second pattern is thicker than the first pattern, indicating the formation of a third pattern (not illustrated) between the first and second patterns, and the interfaces between the first and second patterns form tetragons. When the patterned 3-dimensional complex multilayer structure is used as a light guide plate or a diffusion plate, a sufficient front luminance can be achieved without the need for an additional light collecting sheet. When this pattern is formed on an optical sheet, the ability of the patterned optical sheet to collect light is comparable to that of two conventional optical sheets.

(37) Each of the sides of the tetragons formed at the interfaces between the first and second patterns is preferably from 1 to 5000 m in length. If the length is smaller than the lower limit defined above, the patterning is difficult and the production of a mold is a very laborious work. Meanwhile, if the length is larger than the upper limit defined above, the 3-dimensional complex multilayer structure is visually discernible in an optical component, and as a result, a uniform luminance of the optical component cannot be ensured, thus being unsuitable for use in a display. However, the upper limit of the length is not particularly restricted in applications other than displays.

(38) The 3-dimensional complex multilayer structure of the present invention may also have parallel curves and parallel zigzag lines as well as parallel lines that are orthogonal to each other. The interfaces between the first and second patterns may form polygons other than tetragons, circles, ellipses, or combinations thereof.

(39) For example, FIG. 3 illustrates a combination of a first pattern of parallel curves and a second pattern of parallel curves orthogonal to the parallel direction of the first pattern, and the interfaces between the first and second patterns form tetragons.

(40) FIG. 4 illustrates a combination of a first pattern of parallel curves and a second pattern of parallel lines orthogonal to the parallel direction of the first pattern, and the interfaces between the patterns form tetragons.

(41) FIG. 5 illustrates a combination of a first pattern of parallel zigzag lines and a second pattern of parallel zigzag lines orthogonal to the parallel direction of the first pattern, and the interfaces between the patterns form circles.

(42) FIG. 6 illustrates a combination of a first pattern of parallel zigzag lines and a second pattern of parallel lines orthogonal to the parallel direction of the first pattern, and the interfaces between the patterns form circles.

(43) FIG. 7 illustrates a combination of a first pattern of parallel lines and a second pattern of parallel zigzag lines orthogonal to the parallel direction of the first pattern, and the interfaces between the patterns form circles and tetragons.

(44) The first and second patterns are microstructures made of a heat- or active energy ray-curable resin.

(45) The active energy ray-curable resin refers to a resin that can be cured by irradiation with active energy rays. Most conventional resins are cured by heating. However, during heat curing, thermal expansion occurs due to a difference between a maximum temperature upon heating and room temperature upon cooling, leading to volume shrinkage. Heat curing itself also causes volume shrinkage. As a result of the volume shrinkage, cracks are likely to occur and precise dimensions are difficult to attain. Further, thermal residual stress arising during heat curing shortens the life of components, requires much thermal energy for curing, limits the size of molded products, and requires a long time for curing.

(46) In contrast, curing by active energy rays does not cause the problems of heat curing (e.g., crack, low precision, and thermal residual stress), is less energy and time consuming, and does not limit the size of molded products.

(47) A cross section perpendicular to the parallel directions of the first and second patterns may be in the form of a wave. In the wavy cross section, a pair of adjacent troughs and a crest between the troughs may correspond to the three corners of a triangle, both end points of a chord and one point of an arc of a segment of a circle, both end points of a chord and one point of an arc of a segment of an ellipse, or the two corners and one round-edged corner of a triangle.

(48) FIG. 8 illustrates one embodiment of the first or second pattern of the 3-dimensional complex multilayer structure according to the present invention in which a pair of adjacent troughs and a crest between the troughs correspond to the three corners of a triangle in a wavy cross section. When the second pattern is used, the third pattern may be formed to a thickness T.

(49) When the patterned structure of the present invention is used as a prism sheet, rays of light from two different directions can be collected simultaneously. At this time, the included angle (denoted by A in FIG. 8) between the crests is preferably from 30 to 150. If the included angle is smaller than 30, light is totally reflected and cannot pass through the structure, molding is difficult to perform, and the sharp tips of the structure are easily broken into pieces, resulting in poor handling performance. Meanwhile, if the included angle exceeds 150, the structure is close to a plane rather than a prism and is thus ineffective in light collection. As a result, light is scattered, leading to a reduction in luminance.

(50) FIG. 10 illustrates one embodiment of the first or second pattern of the 3-dimensional complex multilayer structure according to the present invention in which a pair of adjacent troughs and a crest between the troughs correspond to both end points of a chord and one point of an arc of a segment of a circle, respectively, in a wavy cross section. When the patterned 3-dimensional complex multilayer structure is used as a diffusion sheet, it spreads light, ensuring a wide viewing angle and a uniform luminance.

(51) FIG. 11 illustrates one embodiment of the first or second pattern of the 3-dimensional complex multilayer structure according to the present invention in which a pair of adjacent troughs and a crest between the troughs correspond to both end points of a chord and one point of an arc of a segment of an ellipse, respectively, in a wavy cross section. When the 3-dimensional complex multilayer structure is in the form of a diffusion sheet, it spreads light, ensuring a wide viewing angle and a uniform luminance, as in the segment of the circle.

(52) When the 3-dimensional complex multilayer structure of the present invention is used as an optical component, the height H from the trough to the crest in the wavy cross section is preferably from 1 to 500 m. If the height is smaller than the lower limit defined above, the effects of the pattern resulting from the step height disappear. Meanwhile, if the height exceeds the upper limit defined above, the 3-dimensional complex multilayer structure is visually discernible, causing poor visibility, and is excessively large in thickness.

(53) When it is intended to use the 3-dimensional complex multilayer structure including the first and second patterns as an optical sheet, its refractive index is preferably adjusted to 1.3 to 1.9.

(54) The 3-dimensional complex multilayer structure may be used without limitation in any optical component that can guide and control the path of light. Examples of suitable optical components include various kinds of optical sheets capable of light collection or dispersion, light guide plates for edge type liquid crystal displays, diffusion plates for direct type liquid crystal displays, and light collecting sheets and light collecting plates for solar power generation devices.

(55) In addition to the above optical components, the 3-dimensional complex multilayer structure of the present invention can be used in optical components for displays, such as color filters, next generation displays and display devices, such as TFTs, OTFTs, oxide TFTs, flexible displays, and transparent displays, next generation 3-dimensional semiconductors, dry adhesion based on the use of fine ciliary structures, micro/nano piezoelectric devices, lighting optical components, and biocell/virus research using micropatterns, but are not limited to these applications.

(56) The 3-dimensional complex multilayer structure of the present invention may be manufactured using a mask mold, as illustrated in FIGS. 14 and 15.

(57) First, a second base mold 12 is prepared. The second base mold 12 is formed with a first pattern selected from the group consisting of parallel lines, parallel curves, parallel zigzag lines, and combinations thereof which do not meet each other, on one surface thereof [step (f) of FIG. 14 and step (f) of FIG. 15].

(58) Separately, a mask mold 60 or 60 is prepared. The mask mold 60 or 60 includes a first support 20 in the form of a flexible or rigid plate through which active energy rays transmit, a mask 30 repetitively formed or perforated with polygons, circles, ellipses or combinations thereof on one surface of the first support 20 and through which active energy rays do not transmit, and a patterned layer adapted to cover the first support 20 and the mask 30 and having a second pattern formed on the surface opposite to the surface facing the first support 20 or a second pattern formed in an exposed portion of one surface of the first support 20 [step (f) of FIG. 14 and step (f) of FIG. 15].

(59) The second pattern is not parallel to the first pattern and may be selected from the group consisting of parallel lines, parallel curves, parallel zigzag lines, and combinations thereof which do not meet each other.

(60) Then, a resin 42 for a second mold is applied onto the first pattern of the second base mold 12 or the mask mold 60 or 60, and the second base mold 12 is pressed against the mask mold 60 or 60, which is separated from the second base mold 12 by the resin 42, such that the parallel direction of the second pattern is not parallel to that of the first pattern [step (f) of FIG. 14 and step (f) of FIG. 15]. More preferably, the second base mold 12 is pressed against the mask mold 60 or 60, which is separated from the second base mold 12 by the resin 42, such that the parallel direction of the second pattern is orthogonal to the parallel direction of the first pattern.

(61) Subsequently, the mask mold 60 or 60 is pressurized toward the resin 42, and the resin 42 is cured by irradiating the mask mold 60 or 60 with active energy rays or heating the mask mold to form a second mold 52 [step (g) of FIG. 14 and step (g) of FIG. 15].

(62) Then, the second mold 52 and the mask mold 60 or 60 are separated from each other [step (h) of FIG. 14 and step (h) of FIG. 15], and an uncured portion of the resin 42 is removed by dissolution in a solvent [step (i) of FIG. 14 and step (i) of FIG. 15], completing the manufacture of the 3-dimensional complex multilayer structure according to the present invention [step (j) of FIG. 14 and step (j) of FIG. 15].

(63) The 3-dimensional complex multilayer structure 70 thus manufactured may be used as a master to produce a mold, which may be used to manufacture another 3-dimensional complex multilayer structure (see FIG. 16).

(64) Referring specifically to FIG. 16, the multilayer structure 70 manufactured by the method illustrated in FIG. 14 or 15 is used as a master. First, a resin for a third mold 44 is applied to the master, and a second support 25 is brought into close contact with the resin 44 [step (k) of FIG. 16]. The second support 25 is pressurized toward the master 70, and the resin 44 is cured by irradiating the second support 25 with active energy rays or heating the second support 25 to form a third mold 54 [step (l) of FIG. 16]. Then, the third mold 54 is separated from the master 70 [step (m) of FIG. 16].

(65) Subsequently, a resin 84 for patterning is applied to the third mold 54 or a substrate 82, and the third mold 54 is pressed against the substrate 82, which is separated from the third mold 54 by the resin 84 [step (n) of FIG. 16]. The resin 84 is cured by irradiating the third mold 54 or the substrate 82 with active energy rays or heating the third mold 54 or the substrate 82 to form a pattern 86 [step (o) of FIG. 16]. The 3-dimensional complex multilayer structure 80 formed with the pattern 86 is separated from the third mold 54 [step (p) of FIG. 16].

(66) The first and second patterns may also be formed on either or both surfaces of the multilayer structure. This is distinguished from the prior art in which separate patterns are formed on both surfaces of a single multilayer structure. When a multilayer structure whose both surfaces are patterned is used as an optical sheet, rays of light from two different directions cannot be effectively collected, and as a result, the intended effects of the present invention such as a reduction in the number of optical sheets or a remarkable rise in front luminance, cannot be sufficiently attained. However, the effects of the prior art multilayer structure are not limited in applications other than optical sheets.

(67) In recent years, many complex (prism) optical sheets have been developed in which two prism sheets for different directions are attached using an adhesive or pressure-sensitive adhesive so as to overlap each other. The optical sheets enable simultaneous collection of rays of light from two directions but use two sheets of supports (PET), entailing high production costs. Another problem of the optical sheets is that the distal prism patterns are crushed after attachment, losing their optical functions. In contrast, the multilayer structure of the present invention is advantageous in terms of production cost and structural stability because prisms for two directions can be formed on one surface of a single support sheet (see FIG. 29).

(68) The mask mold 60 used in the manufacture of the 3-dimensional complex multilayer structure according to the present invention includes a first support 20 in the form of a flexible or rigid plate through which active energy rays transmit, a mask 30 repetitively formed or perforated with polygons, circles, ellipses or combinations thereof on one surface of the first support 20 and through which active energy rays do not transmit, and a patterned layer adapted to cover the first support 20 and the mask 30 and having a pattern formed on the surface opposite to the surface facing the first support.

(69) The mask mold 60 includes a first support 20 in the form of a flexible or rigid plate through which active energy rays transmit, a mask 30 repetitively formed or perforated with polygons, circles, ellipses or combinations thereof on one surface of the first support 20 and through which active energy rays do not transmit, and a pattern formed in a portion, where the first support 20 is exposed, of one surface of the first support 20 on which the mask 30 is formed.

(70) Preferably, an adhesion promoting layer is further formed between the pattern layer and each of the first support 20 and the mask 30 to prevent the pattern layer or the pattern from falling off.

(71) The pattern layer, the pattern or the adhesion promoting layer may be cured by active energy rays or heating. As described previously, during heat curing, thermal expansion occurs due to a difference between a maximum temperature upon heating and room temperature upon cooling, leading to volume shrinkage. Heat curing itself also causes volume shrinkage. As a result of the volume shrinkage, cracks are likely to occur and precise dimensions are difficult to attain. Further, thermal residual stress arising during heat curing shortens the life of components, requires much thermal energy for curing, limits the size of molded products, and requires a long time for curing. In contrast, curing by active energy rays is less energy and time consuming and does not limit the size of molded products. Due to these advantages, curing by active energy rays is widely used.

(72) As in the 3-dimensional complex multilayer structure, the first and second patterns of the mask mold may be patterns selected from the group consisting of the group consisting of parallel lines, parallel curves, parallel zigzag lines, and combinations thereof which do not meet each other.

(73) Particularly, the mask 30 may be a printed colored coating or a deposited opaque metal.

(74) There is no restriction on the method for producing the mask molds 60 and 60. For example, the mask molds 60 and 60 may be produced by an imprinting process, as illustrated in FIGS. 12 and 13. Inkjet or screen printing may be used to produce the mask molds 60 and 60.

(75) With reference to FIGS. 12 and 13, a detailed description will be given of the methods for producing the mask molds 60 and 60 by an imprinting process. First, a portion of one surface of a first support 20 in the form of a flexible or rigid plate through which active energy rays transmit is printed to form a colored coating through which active energy rays do not transmit [step (a) of FIG. 12 and step (a) of FIG. 13]. The colored coating may be repetitively printed or perforated with polygons, circles, ellipses or combinations thereof.

(76) If needed, a resin for an adhesion promoting layer may be applied to the surface of the first support 20 on which the colored coating is printed and may be cured to form an adhesion promoting layer. The adhesion promoting layer serves to further strengthen the binding of the first support 20 to a first mold 50, which will be described below.

(77) A resin 40 for a first mold is applied to a first base mold 10 through which active energy rays transmit or the surface of the first support 20 on which the colored coating is printed, and the first support 20 is pressed against the first base mold 10, which is separated from the first support by the resin 40 [step (b) of FIG. 12 and step (b) of FIG. 13].

(78) Subsequently, the first support 20 is pressurized toward the first base mold 10 and the resin is cured by irradiating the first base mold 10 with active energy rays or heating the first base mold 10 to form the mask mold 60 or 60 [step (c) of FIG. 12 and step (c) of FIG. 13]. Step (c) of FIG. 12 illustrates irradiation with active energy rays onto the first base mold and irradiation with active energy rays onto the first support.

(79) If needed, the method may further include removing an uncured portion of the resin 40 by dissolution in a solvent.

(80) Finally, the mask mold 60 or 60 is separated from the first base mold 10 [step (d) of FIG. 12 and step (d) of FIG. 13]. The mask mold 60 or 60 is used in the manufacture of the 3-dimensional complex multilayer structure 80 according to the present invention [step (e) of FIG. 12 and step (e) of FIG. 13].

(81) Alternatively, the mask mold 60 or 60 may be produced by the following procedure. First, a portion of one surface of a first support 20 in the form of a flexible or rigid plate through which active energy rays transmit, is masked with a shadow mask and the masked first support is deposited with an opaque metal through which active energy rays do not transmit [step (a) of FIG. 12 and step (a) of FIG. 13]. The opaque metal may be repetitively deposited or perforated with polygons, circles, ellipses or combinations thereof.

(82) If needed, a resin for an adhesion promoting layer may be applied to the surface of the first support 20 on which the opaque metal is deposited and may be cured to form an adhesion promoting layer. The adhesion promoting layer serves to further strengthen the binding of the first support 20 to a first mold 50, which will be described below.

(83) A resin 40 for a first mold is applied to a first base mold 10 through which active energy rays transmit or the surface of the first support 20 on which the opaque metal is deposited, and the first support 20 is pressed against the first base mold 10, which is separated from the first support by the resin 40 [step (b) of FIG. 12 and step (b) of FIG. 13].

(84) Subsequently, the first support 20 is pressurized toward the first base mold 10 and the resin 40 is cured by irradiating the first base mold 10 with active energy rays or heating the first base mold 10 to form the mask mold 60 or 60 [step (c) of FIG. 12 and step (c) of FIG. 13].

(85) If needed, the method may further include removing an uncured portion of the resin 40 by dissolution in a solvent.

(86) Finally, the mask mold 60 or 60 is separated from the first base mold 10 [step (d) of FIG. 12 and step (d) of FIG. 13]. The mask mold 60 or 60 is used in the manufacture of the 3-dimensional complex multilayer structure 80 according to the present invention [step (e) of FIG. 12 and step (e) of FIG. 13].

(87) The 3-dimensional complex multilayer structure of the present invention will be explained in terms of its effects when applied to an optical component.

(88) FIG. 17 is an image showing one embodiment of the present invention in which the first pattern is a prism pattern and the second pattern is a prism pattern orthogonal to the parallel direction of the first pattern, FIG. 18 is a partially enlarged view of FIG. 17.

(89) FIGS. 19 to 22 are diagrams showing the results of analysis of viewing angles for a conventional light guide plate (FIG. 19), a combination of a diffusion plate with the light guide plate (FIG. 20), a combination of a diffusion plate with the light guide plate (FIG. 20), a combination of a diffusion plate and a first light collecting sheet with the light guide plate (FIG. 21), and a combination of a diffusion plate, a first light collecting sheet, and a second light collecting sheet with the light guide plate (FIG. 22). High luminance portions of the structures are colored red. A red color was observed in the central portion of the structure of FIG. 22 in which the diffusion plate, the first light collecting sheet, and the second light collecting sheet were combined with the conventional light guide plate. This observation demonstrates the necessity of two light collecting sheets in the conventional light guide plate.

(90) In contrast, a higher luminance was observed in the 3-dimensional complex multilayer structure of the present invention as a light guide plate (FIG. 23) than in the conventional light guide plate (FIG. 19). When a diffusion plate was combined with the 3-dimensional complex multilayer structure of the present invention, the central portion of the combined structure turned red (FIG. 24). These results demonstrate that there is no need for a separate light collecting sheet. Therefore, the use of the 3-dimensional complex multilayer structure according to the present invention is economically desirable and can contribute to a reduction in the thickness of a final device.

(91) The luminance of a combination of a diffusion plate with a conventional light guide plate is shown in FIG. 25. A combination of the multilayer structure of the present invention as a single optical sheet (FIG. 27) with the combination of FIG. 25 showed a higher luminance as a whole than a combination of two optical sheets with a conventional light guide plate (FIG. 26). In conclusion, a reduced number of optical sheets is required when the multilayer structure of the present invention is used.

(92) While the present invention has been described herein with reference to its preferred embodiments, these embodiments do not serve to limit the invention and those skilled in the art will appreciate that various modifications can be made thereto without departing from the spirit and scope of the present invention. Therefore, the scope of the present invention should be defined by the following claims and their equivalents.

(93) As described above, the 3-dimensional complex multilayer structure of the present invention includes different complex patterns. In contrast, a conventional device has a kind of simple pattern. In addition, the 3-dimensional complex multilayer structure of the present invention can be manufactured by a simple process. Therefore, the 3-dimensional complex multilayer structure of the present invention can find application in various fields, including, but not limited to, optical components for displays (e.g., light guide plates, diffusion plates, prisms, and color filters), next generation displays and display devices (e.g., TFTs, OTFTs, oxide TFTs, flexible displays, and transparent displays), next generation 3-dimensional semiconductors, dry adhesion based on the use of fine ciliary structures, micro/nano piezoelectric devices, lighting optical components, and biocell/virus research using micropatterns.