CN113183447A - Fresnel microstructure mold, Fresnel membrane preparation method and orthographic projection screen - Google Patents

Fresnel microstructure mold, Fresnel membrane preparation method and orthographic projection screen Download PDF

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Publication number
CN113183447A
CN113183447A CN202110476772.2A CN202110476772A CN113183447A CN 113183447 A CN113183447 A CN 113183447A CN 202110476772 A CN202110476772 A CN 202110476772A CN 113183447 A CN113183447 A CN 113183447A
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Prior art keywords
fresnel
microstructure
layer
fresnel microstructure
projection screen
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CN202110476772.2A
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CN113183447B (en
Inventor
周辉
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Qingdao Hisense Laser Display Co Ltd
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Qingdao Hisense Laser Display Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/022—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing characterised by the disposition or the configuration, e.g. dimensions, of the embossments or the shaping tools therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B32B27/365—Layered products comprising a layer of synthetic resin comprising polyesters comprising polycarbonates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02—Physical, chemical or physicochemical properties
    • B32B7/023—Optical properties
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03B—APPARATUS OR ARRANGEMENTS FOR TAKING PHOTOGRAPHS OR FOR PROJECTING OR VIEWING THEM; APPARATUS OR ARRANGEMENTS EMPLOYING ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ACCESSORIES THEREFOR
    • G03B21/00—Projectors or projection-type viewers; Accessories therefor
    • G03B21/54—Accessories
    • G03B21/56—Projection screens
    • G03B21/60—Projection screens characterised by the nature of the surface
    • G03B21/602—Lenticular screens
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • B29C59/022—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing characterised by the disposition or the configuration, e.g. dimensions, of the embossments or the shaping tools therefor
    • B29C2059/023—Microembossing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2007/00—Flat articles, e.g. films or sheets
    • B29L2007/002—Panels; Plates; Sheets

Abstract

The invention discloses a Fresnel microstructure die, a Fresnel membrane preparation method and an orthographic projection screen, relates to the technical field of projection screens, and is used for solving the problem that the size of a Fresnel membrane capable of being processed is limited due to the size limitation of a conical roller in the prior art. The Fresnel microstructure mould is in a long strip shape, one side of the Fresnel microstructure mould is provided with a plurality of processing teeth, and the processing teeth are arranged along the length direction of the Fresnel microstructure mould. The Fresnel microstructure mold is used for preparing a Fresnel membrane with a longer size.

Description

Fresnel microstructure mold, Fresnel membrane preparation method and orthographic projection screen
Technical Field
The invention relates to the technical field of projection screens, in particular to a Fresnel microstructure die, a Fresnel membrane preparation method and an orthographic projection screen.
Background
The Fresnel membrane comprises a base layer and a Fresnel lens layer which are arranged in a stacked mode, wherein a plurality of Fresnel microstructures which are regularly arranged are arranged on one side, away from the base layer, of the Fresnel lens layer.
In the prior art, when a fresnel membrane is processed, a conical roller is usually used to process a fresnel microstructure on a fresnel lens layer. As shown in fig. 1, the tapered roller 01 includes a roller body 011, which is tapered. As shown in fig. 2, a plurality of annular ribs 0111 are layered on an outer side surface of the roller body 011. The diameter of each annular projected ridge 0111 gradually decreases in the X direction in fig. 2. The surface profile of the roller body 011 cut by a tangent plane of the axis of the roller body 011 is matched with the profile of the Fresnel microstructure cut by a plane formed by the bidirectional extension of the radius of the Fresnel microstructure along the direction parallel to the axis of the Fresnel microstructure. As shown in fig. 3, in use, the fresnel microstructure is formed by rolling the tapered roller 01 on the fresnel lens layer 02.
The annular convex edge 0111 on the roller body 011 is machined through the rotation of a main shaft of the ultra-precision turning machine tool and the linear motion of the tool rest along the axial direction and the radial direction. When the diameter of the large-diameter end of the roller body 011 or the length of the roller body 011 is large to a certain extent, the maximum rotation radius and the maximum cutting length working range of the ultra-precise turning machine tool are exceeded, and the ultra-precise turning machine tool cannot process the roller body 011. This results in a limitation in both the axial and radial lengths of the roller body 011, which in turn results in a limitation in the size of the fresnel film that can be processed by the tapered roller 01.
Disclosure of Invention
The invention aims to provide a Fresnel microstructure die, a method for preparing a Fresnel membrane by using the Fresnel microstructure die and an orthographic projection screen comprising the Fresnel membrane prepared by the method, which are used for solving the problem that the size of the Fresnel membrane which can be processed is limited due to the size limitation of a conical roller in the prior art.
In order to achieve the purpose, the technical scheme is as follows:
one aspect of the embodiments of the present application provides a fresnel microstructure mold. The Fresnel microstructure mould is in a long strip shape, one side of the Fresnel microstructure mould is provided with a plurality of processing teeth, and the processing teeth are arranged along the length direction of the Fresnel microstructure mould.
Because the fresnel microstructure mould is rectangular form, and realize fresnel microstructure's processing through the processing tooth that sets up in its one side, so when preparation fresnel microstructure mould, do not adopt the processing of rotary cutting class, can not appear because surpassing ultra-precision lathe work machine's the biggest cutting range and lead to the unable processing of fresnel microstructure mould, so fresnel microstructure mould can be makeed longer, and then the size of the fresnel diaphragm of using this fresnel microstructure mould preparation can be great, only need according to fresnel diaphragm's size requirement preparation adaptation length fresnel microstructure mould can. For example, the fresnel microstructure mold may be etched by a femtosecond laser, and in short, the length of the fresnel microstructure mold is not limited when it is manufactured. In addition, because only need process out the processing tooth in one side of fei nieer microstructure mould just, compare and set up annular bead on fei nieer microstructure mould, practiced thrift the cost of preparation fei nieer microstructure mould greatly.
Optionally, the processing teeth have a first inclined surface on one side in the tooth length direction, and the tooth length direction of the processing teeth is perpendicular to the length direction of the fresnel microstructure mold; the first inclined plane extends to the tooth top of the machining tooth, and an included angle between the first inclined plane and the tooth top of the machining tooth is an obtuse angle. When the Fresnel microstructure mould is used, the Fresnel microstructure can be processed in a sliding propulsion mode, and the first inclined plane is arranged, so that the first inclined plane can be used as a windward plane, and therefore resistance of the Fresnel microstructure mould in propulsion can be reduced. In addition, the first inclined plane can be pressed down with the fresnel lens layer material that processing tooth corresponds to reduce the quantity of the fresnel lens layer material that needs to be scraped, avoid the waste of material. Meanwhile, after the Fresnel lens layer material corresponding to the processing teeth is pressed down, the Fresnel lens layer material beside the Fresnel lens layer can be prevented from being driven to deform in the final process of being scraped by the processing teeth, and the final Fresnel microstructure forming is further influenced.
Optionally, the fresnel microstructure mold comprises a mold body, and the processing teeth are arranged on the mold body; the die body is provided with a second inclined plane which is connected with the first inclined plane and is coplanar. In this way, the gap between the second inclined surface and the fresnel lens layer can be used to accommodate the material extruded by the machined teeth during the cutting process of the machined teeth.
Another aspect of the embodiments of the present application provides a method for manufacturing a fresnel membrane using the fresnel microstructure mold according to any of the embodiments described above. The method comprises the following steps: coating optical resin on the substrate layer, and performing semi-curing treatment to form a layer to be processed; processing a Fresnel microstructure on the layer to be processed by utilizing the processing teeth on the Fresnel microstructure mold; the optical resin is subjected to a curing treatment.
Because the fresnel microstructure mould is rectangular form, and realize fresnel microstructure's processing through the processing tooth that sets up in its one side, so when preparation fresnel microstructure mould, do not adopt the processing of rotary cutting class, can not appear because surpassing ultra-precision lathe work machine's the biggest cutting range and lead to the unable processing of fresnel microstructure mould, so fresnel microstructure mould can be makeed longer, and then the size of the fresnel diaphragm of using this fresnel microstructure mould preparation can be great, only need according to fresnel diaphragm's size requirement preparation adaptation length fresnel microstructure mould can. For example, the fresnel microstructure mold may be etched by a femtosecond laser, and in short, the length of the fresnel microstructure mold is not limited when it is manufactured. In addition, because only need process out the processing tooth in one side of fei nieer microstructure mould just, compare and set up annular bead on fei nieer microstructure mould, practiced thrift the cost of preparation fei nieer microstructure mould greatly.
Optionally, the fresnel microstructure mold is slid and advanced when in use to form a fresnel microstructure. Furthermore, the continuity of the processed Fresnel microstructure is better.
Optionally, when the fresnel microstructure mold is pushed in a sliding manner, the fresnel microstructure mold is pushed in a rotating manner by taking a set axis as a rotation center line to form a coaxially arranged fresnel microstructure, the set axis is perpendicular to the base layer, and the length of the fresnel microstructure mold extends along the radial direction of the rotation path. Furthermore, Fresnel microstructures arranged in an annular array can be processed.
Optionally, the thickness of the layer to be processed ranges from 10 μm to 100 μm.
Optionally, the light transmittance of the base layer is 25% to 90%.
In another aspect of the embodiments of the present application, there is provided an orthographic projection screen, which includes a surface layer, a fresnel membrane prepared by using the method according to any one of the embodiments, and a reflective layer, wherein the surface layer and the fresnel membrane are sequentially stacked.
Since the front projection screen provided by the embodiment of the application comprises the Fresnel membrane prepared by the method of any one of the embodiments, the Fresnel membrane and the front projection screen can solve the same technical problem and achieve the same technical effect.
Optionally, the surface layer comprises an anti-reflection film. The antireflection film is arranged, so that the reflection of light on the surface of the orthographic projection screen can be reduced, and the light transmission quantity of the orthographic projection screen can be improved.
Optionally, the antireflection film is provided with a plurality of layers, and the refractive index of the antireflection film close to the fresnel membrane is larger than that of the antireflection film far away from the fresnel membrane. Further improving the light transmission of the front projection screen.
Optionally, the substrate layer includes a first substrate layer and a second substrate layer, and the first substrate layer is disposed on a side of the second substrate layer away from the light-reflecting layer; optical scattering particles are distributed in the second substrate layer. The viewing angle of the orthographic projection screen can be improved by dividing the substrate layer into a first substrate layer and a second substrate layer, and distributing the optical scattering particles in the second substrate layer.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the description of the embodiments are briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.
FIG. 1 is a schematic structural view of a conical roll described in the background art;
FIG. 2 is an enlarged view of portion A of FIG. 1;
FIG. 3 is a schematic diagram of a prior art process for forming a Fresnel lens layer with a conical roll;
FIG. 4 is a schematic cross-sectional view of a Fresnel membrane according to some embodiments of the present disclosure;
FIG. 5 is a schematic layout of Fresnel microstructures of Fresnel membranes according to some embodiments of the present disclosure;
FIG. 6 is a flow chart of a Fresnel membrane production method according to some embodiments of the present disclosure;
FIG. 7 is a schematic structural diagram of a Fresnel microstructure mold according to some embodiments of the present disclosure;
FIG. 8 is a schematic view of a Fresnel membrane cut to size in some embodiments provided by the present disclosure;
FIG. 9 is a schematic illustration of a Fresnel membrane produced using a Fresnel microstructure mold according to some embodiments of the present disclosure;
FIG. 10 is a side view of a Fresnel microstructure mold according to some embodiments of the present disclosure;
FIG. 11 is a side view of a Fresnel microstructure mold according to further embodiments of the present invention;
FIG. 12 is a diagram illustrating the use of Fresnel film produced using a Fresnel microstructure mold according to some embodiments of the present invention;
FIG. 13 is a schematic illustration of a parameter description of a Fresnel lens layer in some embodiments provided by the present invention;
FIG. 14 is a schematic representation of a front projection screen including a Fresnel membrane produced using a Fresnel microstructure mold according to some embodiments of the present disclosure;
fig. 15 is a schematic structural diagram of a front projection screen including a fresnel film produced using a fresnel microstructure mold according to further embodiments of the present invention.
Reference numerals:
01-a conical roller; 011-roller body; 0111-circular convex edge; 02-a fresnel lens layer; 1-a Fresnel membrane sheet; 11-a base layer; 111-a first substrate layer; 112-a second substrate layer; 12-a fresnel lens layer; 121-fresnel microstructure; 1211-a reflecting surface; 1212-light-resistant surface; 122-optically scattering particles; 2-Fresnel microstructure mould; 21-machining teeth; 211 — a first bevel; 212-tooth top; 22-a mould body; 221-a second bevel; 3-setting an axis; 4-a light-reflecting layer; 5-a projector; 51-incident light; 52-outgoing rays; 6-electric lamp; 7-a surface layer; 8-normal; 100-a front projection screen.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In the description of the present invention, it is to be understood that the terms "center", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience of description and simplicity of description, and do not indicate or imply that the referenced devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and thus, are not to be construed as limiting the present invention.
The terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless otherwise specified.
It should be noted that in practical applications, due to the limitation of the precision of the device or the installation error, the absolute parallel or perpendicular effect is difficult to achieve. In the present application, the vertical, parallel or equidirectional description is not an absolute limitation condition, but means that the vertical or parallel structural arrangement can be realized within a preset error range, and a corresponding preset effect is achieved, so that the technical effect of limiting the features can be realized to the maximum extent, and the corresponding technical scheme is convenient to implement and has high feasibility.
In the description of the present invention, it should be noted that the terms "mounted," "connected," and "connected" are to be construed broadly and may be, for example, fixedly connected, detachably connected, or integrally connected unless otherwise explicitly stated or limited. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
As shown in fig. 4, the fresnel membrane 1 includes a base layer 11 and a fresnel lens layer 12, which are sequentially stacked, wherein a fresnel microstructure 121 is disposed on a side of the fresnel lens layer 12 away from the base layer 11, and the fresnel microstructure 121 is an elongated rib disposed on the fresnel lens layer 12. The Fresnel microstructures 121 are arranged, so that an orthographic projection screen using the Fresnel membrane 1 can absorb ambient light, and the interference of the ambient light is reduced; meanwhile, the projection light of the image can be reflected directionally, and the brightness and the contrast of the image are improved.
The fresnel microstructures 121 on the fresnel lens layer 12 generally have two shapes and arrangements. First, as shown in fig. 5, each fresnel microstructure 121 is arc-shaped, and each fresnel microstructure 121 is coaxially disposed. The second fresnel microstructures 121 are linear, and each fresnel microstructure 121 is arranged along a certain linear direction. The method for producing the fresnel film 1 is described below by taking the first fresnel microstructure 121 as an example.
In some embodiments, the method for preparing the fresnel membrane 1 provided by the present application includes S101, S102, and S103 as shown in fig. 6:
s101, coating optical resin on the base layer 11, and performing semi-curing treatment to form a layer to be processed.
The base layer 11 serves as a carrier base for the fresnel membrane 1 for the fresnel lens layer 12 to be attached to. The substrate layer 11 is made of gray organic material or inorganic material with a certain light blocking rate, and may be made of hard material or soft material, and specifically may be: glass, PE (Polyethylene), PET (Polyethylene terephthalate), PVC (Polyvinyl chloride), PMMA (Polymethyl Methacrylate), polycarbonate, etc., and the light transmittance is generally maintained within a range of 25% to 90% to meet the requirements.
It should be noted that the optical resin may be selected from UV glue or thermal curing glue. Under the condition of selecting the UV glue, the semi-curing treatment of the UV glue is realized by irradiation of an ultraviolet lamp. Under the condition of selecting the thermosetting glue, the semi-curing treatment of the thermosetting glue is realized by adopting a heating method.
In some embodiments, in order to reduce the thickness of the fresnel film sheet 1 while satisfying the smooth formation of the fresnel microstructure 121, the thickness of the layer to be processed is controlled to be in the range of 10 μm to 100 μm when the layer to be processed is formed.
S102, processing the Fresnel microstructure 121 on the layer to be processed by utilizing the processing teeth on the Fresnel microstructure mold.
The structure of the fresnel microstructure mold is explained below. As shown in fig. 7, the fresnel microstructure mold 2 is in a strip shape, one side of the fresnel microstructure mold 2 is provided with a plurality of processing teeth 21, and the processing teeth 21 are arranged along the length direction of the fresnel microstructure mold 2. The shape of each machined tooth 21 matches the shape of a groove between adjacent fresnel microstructures 121 on fresnel lens layer 12, and the shape of a tooth groove formed between adjacent machined teeth 21 matches the shape of fresnel microstructures 121.
In this way, the fresnel microstructure 121 can be processed on the layer to be processed through the processing teeth 21 on the fresnel microstructure mold 2.
Because fresnel microstructure mould 2 is rectangular form, and processing tooth 21 only sets up in fresnel microstructure mould 2's one side, so when preparation fresnel microstructure mould 2, only need process fresnel microstructure mould 2's one side to form processing tooth 21 can, it is very convenient. Because only need process out the processing tooth 21 in one side of fresnel microstructure mould 2 just, compare and set up annular bead on fresnel microstructure mould 2, practiced thrift the cost of preparation fresnel microstructure mould 2 greatly.
The machining teeth 21 on the Fresnel microstructure die 2 can be machined by a non-turning machine tool adopting an ultra-precise diamond cutter, in addition, the machining teeth 21 on the Fresnel microstructure die 2 can also be etched by femtosecond laser, and the machining precision can reach the nanometer level.
In the related art, the Fresnel microstructure is formed by rolling a conical roller on a Fresnel lens layer, and then the Fresnel membrane is manufactured. The conical roller is limited by the maximum rotating radius and the maximum cutting length working range of the ultra-precise turning machine tool, and the maximum size of the manufactured Fresnel membrane 1 is smaller than 120 inches. Since the fresnel microstructure mold 2 does not need to be provided with the annular rib, the fresnel microstructure mold can be used for manufacturing the fresnel diaphragm 1 with a size of 120 inches or more, for example, the size of the manufactured fresnel diaphragm 1 can be 120 inches, 135 inches, 150 inches, etc., without being limited by the maximum rotation radius and the maximum cutting length working range of the ultra-precision turning machine tool during processing. The fresnel microstructure mold 2 may be made of stainless steel or an alloy mainly containing Fe, Ni, Ti, Cr, Mn, or other elements.
And S103, curing the optical resin.
After the fresnel microstructure 121 is processed on the layer to be processed, the optical resin is cured. For example, when the optical resin is UV glue, the UV glue is irradiated by an ultraviolet lamp to perform a curing process. When the optical resin is made of the thermosetting glue, the thermosetting glue is heated to realize curing treatment.
As shown in fig. 8, after the fresnel film 1 is processed, a required region (for example, a region B in fig. 8) is cut according to a required size and used in a front projection screen.
In order to ensure the continuity of the fresnel microstructure 121 on the fresnel lens layer 12. In some embodiments, when the fresnel microstructure mold 2 is used to process the fresnel microstructure 121, the fresnel microstructure mold 2 is slid forward to form a linear fresnel microstructure 121.
Therefore, only by continuously sliding and propelling the fresnel microstructure mold 2, the processing teeth 21 on the fresnel microstructure mold 2 can ensure that the continuity of the processed fresnel microstructure 121 is good, and further the projection reflection uniformity of the fresnel membrane 1 is good when in use.
Next, how to machine the fresnel microstructure 121 having a circular arc shape using the fresnel microstructure mold 2 will be described. As shown in fig. 9, when the fresnel microstructure mold 2 is slidingly advanced, the fresnel microstructure mold 2 is rotationally advanced with the set axis 3 as a rotation center line to form a fresnel microstructure 121 coaxially arranged, the set axis 3 is perpendicular to the base layer 11, and the length of the fresnel microstructure mold 2 extends along a radial direction of a rotation path. The end of the fresnel microstructure die 2 close to the set axis 3 is spaced from the set axis 3.
In this way, since the fresnel microstructure mold 2 is rotationally advanced, the traveling path of the processing tooth 21 is in a circular arc shape, and the processed fresnel microstructure 121 is in a circular arc shape.
In order to reduce the resistance of the fresnel microstructure mold 2 during sliding. As shown in fig. 10, in some embodiments, the machining tooth 21 has a first inclined surface 211 on one side in the tooth length direction, and the tooth length direction of the machining tooth 21 is perpendicular to the length direction of the fresnel microstructure mold 2 (the L direction shown in fig. 10 is the tooth length direction of the machining tooth 21); the first inclined surface 211 extends to the tooth top 212 of the machining tooth 21, and an included angle α between the first inclined surface and the tooth top 212 of the machining tooth 21 is an obtuse angle.
In this way, when the fresnel microstructure die 2 processes the fresnel microstructure 121 in a sliding propulsion manner, the side where the first inclined surface 211 is disposed can be the windward side, and in the process of extruding the optical resin by the processing teeth 21, the side corresponding to the advancing direction of the processing teeth 21 has a tip, which reduces the resistance on the processing teeth 21, thereby reducing the resistance in the whole fresnel microstructure die 2 in the propulsion process.
In addition, in the advancing process of the fresnel microstructure mold 2, the processing teeth 21 correspond to grooves between adjacent fresnel microstructures 121, and when the fresnel microstructure mold 2 advances, the first inclined surface 211 can press down most of the optical resin corresponding to the grooves, and finally the grooves are pressed out, so that the fresnel microstructures 121 are formed. Therefore, all the optical resin corresponding to the grooves does not need to be scraped, and the waste of the optical resin is avoided.
Meanwhile, in the processing process, a small amount of optical resin is pressed forward by the processing teeth 21 and scraped off, and the optical resin is pressed down by the first inclined plane 211, so that the probability of deformation of the optical resin beside the optical resin in the process of scraping off the optical resin can be reduced, and the smooth molding of the fresnel microstructure 121 is further ensured.
Since a part of the optical resin may be scraped off during the processing and advance along with the fresnel microstructure mold 2, the optical resin is compacted to prevent the scraped optical resin from accumulating on the optical resin on the advancing path of the processing tooth 21, thereby reducing the difficulty of constructing the fresnel microstructure mold 2. As shown in fig. 11, in some embodiments, the fresnel microstructure mold 2 includes a mold body 22, and the machining teeth 21 are disposed on the mold body 22; the mold body 22 is provided with a second inclined surface 221, and the second inclined surface 221 is connected with the first inclined surface 211 and is coplanar.
In this way, in the forward process of the fresnel microstructure die 2, the optical resin scraped off by the processing tooth 21 can enter the gap between the second inclined surface 221 and the layer to be processed, and then is pushed forward by the second inclined surface 221, so that the scraped optical resin and the optical resin in front of the processing tooth 21 are prevented from being extruded together, and the construction difficulty of the fresnel microstructure die 2 is reduced.
The shape of the fresnel microstructure 121 will be explained below. As shown in fig. 12, each fresnel microstructure 121 includes a reflection surface 1211 and a light-resisting surface 1212, the reflection surfaces 1211 of adjacent fresnel microstructures 121 are connected by the light-resisting surface 1212 of one of the fresnel microstructures 121, and the reflection surface 1211 and the light-resisting surface 1212 of each fresnel microstructure 121 are sequentially spliced to form a side surface of the fresnel lens layer 12 away from the base layer 11.
As shown in fig. 12, when the fresnel membrane 1 is applied to a front projection screen, a light reflecting layer 4 is disposed on the side of the fresnel lens layer 12 away from the base layer 11. The reflective layer 4 is generally formed by coating, chemical deposition or vacuum coating, and the material of the reflective layer 4 may be Ag, Al, Cr, or the like.
The projector 5 is generally provided at the lower front side of the front projection screen (for example, when the front projection screen is used, it is laid out along a vertical plane, and the same will be described below). In this way, the incident light 51 emitted from the center of the light source of the projector 5 is irradiated on the reflection surface 1211 of the fresnel microstructure 121 and then reflected into the horizontal emergent light 52, and the emergent light 52 is irradiated to the viewer. Ambient light (e.g., light from a rooftop electric light 6) impinges on the light-resistant surface 1212 of the fresnel microstructure 121 and is reflected away from the viewer.
Since the projector 5 is disposed at the lower front of the front projection screen, the incident angles of the light beams emitted from the projector 5 when the light beams irradiate on the different reflecting surfaces 1211 are different, and in order to ensure that the outgoing light beams 52 reflected by the reflecting surfaces 1211 of the fresnel microstructures 121 can be horizontally outgoing, the included angles between the reflecting surfaces 1211 and the base layer 11 need to be set differently, and the angles should be specially set.
The angle between each reflecting surface 1211 and the substrate layer 11 will be described. As shown in fig. 13, an angle θ between a reflective surface 1211 of the n-th fresnel microstructure 121 from bottom to top and the base layer 11 is defined for the fresnel film 1 in an orthographic projection screenn，θnSatisfies the following conditions:
Figure BDA0003047665350000101
wherein k is the refractive index of the selected optical resin; beta is anSatisfies the following conditions:
Figure BDA0003047665350000102
where h is a distance between the lower end of the fresnel lens layer 12 and the center of the light source of the projector 5 in the vertical direction (i.e., Y direction in fig. 13), R is a distance between the center of the light source of the projector 5 and the fresnel lens layer 12 in the direction perpendicular to the fresnel lens layer 12 (i.e., Z direction in fig. 13, and Z direction is perpendicular to Y direction at the same time), and d is a pitch of the fresnel microstructures 121, and the pitch is equal to a distance between the lower ends of the reflecting surfaces 1211 corresponding to the adjacent fresnel microstructures 121 in the arrangement direction of the adjacent fresnel microstructures 121.
The angle between the light-blocking surface 1212 of the nth fresnel microstructure 121 from bottom to top and the normal 8 perpendicular to the substrate layer 11 is αn，αnSatisfies the following conditions:
αn＝2θn
wherein the normal 8 extends in the Z-direction in fig. 13.
The included angle between each reflecting surface 1211 and the substrate layer 11 and the included angle between each light-resisting surface 1212 and the normal line 8 perpendicular to the substrate layer 11 can be calculated according to the above formula, and then the line type of the machining teeth 21 on the fresnel microstructure mold 2 can be designed according to the data.
It should be noted that, in order to improve the projection effect of the front projection screen, the size of the pitch d does not exceed one pixel of the projection image at most.
In some embodiments, each fresnel microstructure 121 is divided into a plurality of groups, the R values corresponding to each fresnel microstructure 121 in the same group are the same, and the R values of the fresnel microstructures 121 in different groups are different, so that the front projection screen using the fresnel membrane 1 can obtain a plurality of focuses, and each focus can be selected according to actual requirements when in use (the focus is actually the position of the light source center of the projector 5 and is located on the axis of the circular arc-shaped fresnel microstructure 121).
An example of a front projection screen using the fresnel membrane 1 described above will be described below. As shown in fig. 14, in some embodiments, the front projection screen 100 includes a surface layer 7, a fresnel membrane 1, and a reflective layer 4, which are sequentially stacked. The surface layer 7 is disposed on a side of the base layer 11 away from the fresnel lens layer 12, and the reflective layer 4 is disposed on a side of the fresnel lens layer 12 away from the base layer 11. Because the fresnel membrane 1 only includes one substrate layer 11 and the whole front projection screen 100 has no other substrate layer, the thickness of the front projection screen 100 is relatively thin, and the front projection screen 100 is relatively light in weight and is relatively convenient to use and transport.
In some embodiments, the surface layer 7 may include at least one antireflection film, which may substantially reduce the reflection of light on the surface of the front projection screen 100, so as to improve the light transmission of the front projection screen 100. In the case where the antireflection film includes a plurality of layers, the refractive index of the antireflection film closer to the fresnel film sheet 1 is larger, and the refractive index of each layer of the antireflection film ranges from 1.3 to 1.6. The thickness of each layer of antireflection film is set to be 115nm-180 nm. MgF can be selected as the material of the antireflection film.
In other embodiments, in order to improve the wear resistance of the front projection screen 100, the surface layer 7 may comprise an anti-wear layer, and in the case of an anti-reflection film, the anti-reflection film is disposed between the anti-wear layer and the fresnel film sheet 1. In order to prevent the light from generating mirror reflection on the surface of the front projection screen 100 and further generating images on the ceiling, the haze value of the surface of the abrasion-resistant layer far away from the fresnel membrane 1 is set to be 12% -20%. The material of the wear-resistant layer can be silicon dioxide, aluminum oxide or the mixture of the silicon dioxide and the aluminum oxide.
In order to improve the viewing angle of the front projection screen 100. As shown in fig. 14, optical scattering particles 122 are distributed in the fresnel lens layer 12, and the optical scattering particles 122 can diffuse the light entering the front projection screen 100, thereby improving the viewing angle of the front projection screen 100. The optical scattering particles 122 may be silicon dioxide, aluminum oxide, titanium dioxide, or the like.
In other embodiments, as shown in fig. 15, the front projection screen 100 includes the surface layer 7, the fresnel membrane 1, and the reflective layer 4, which are sequentially stacked. The surface layer 7 is disposed on a side of the base layer 11 away from the fresnel lens layer 12, and the reflective layer 4 is disposed on a side of the fresnel lens layer 12 away from the base layer 11. In this embodiment, the substrate layer 11 comprises a first substrate layer 111 and a second substrate layer 112, wherein the first substrate layer 111 is provided on a side of the second substrate layer 112 facing away from the light-reflecting layer 4. When the fresnel membrane 1 is manufactured, a layer to be processed is formed on the side of the second substrate layer 112 away from the first substrate layer 111.
Based on this, in order to improve the viewing angle of the front projection screen 100, as shown in fig. 15, the second substrate layer 112 has optical scattering particles 122 distributed therein. The optical scattering particles 122 may be silicon dioxide, aluminum oxide, titanium dioxide, or the like.
In some embodiments, the material of the second substrate layer 112 may be optical resin (e.g., UV glue or thermal curing glue), when the fresnel membrane 1 is manufactured, the optical resin on which the optical scattering particles 122 are distributed is coated on the first substrate layer 111, then the optical resin is cured, and after the second substrate layer 112 is cured and molded, the fresnel lens layer 12 is manufactured on the side of the second substrate layer 112 away from the first substrate layer 111.
The structure and the using method of the fresnel microstructure mold are the same as those of the fresnel microstructure mold 2 used in the method for preparing the fresnel diaphragm 1, and are not described herein again.
In the description herein, particular features, structures, materials, or characteristics may be combined in any suitable manner in any one or more embodiments or examples.
The above description is only for the specific embodiments of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.

Claims (12)

1. The Fresnel microstructure die is characterized in that the Fresnel microstructure die is long, a plurality of processing teeth are arranged on one side of the Fresnel microstructure die, and the processing teeth are distributed along the length direction of the Fresnel microstructure die.
2. The fresnel microstructure die of claim 1, wherein the machined teeth have a first slope on one side of a tooth length direction, and the tooth length direction of the machined teeth is perpendicular to a length direction of the fresnel microstructure die; the first inclined plane extends to the tooth top of the machining tooth, and an included angle between the first inclined plane and the tooth top of the machining tooth is an obtuse angle.
3. The Fresnel microstructure die as claimed in claim 2, wherein the Fresnel microstructure die comprises a die body, and the processing teeth are arranged on the die body; and a second inclined plane is arranged on the die body, and the second inclined plane is connected with the first inclined plane and is coplanar.
4. A method of producing a fresnel film sheet using a fresnel microstructure mold according to any one of claims 1 to 3, the method comprising:
coating optical resin on the substrate layer, and performing semi-curing treatment to form a layer to be processed;
processing a Fresnel microstructure on the layer to be processed by utilizing the processing teeth on the Fresnel microstructure mould;
and curing the optical resin.
5. A method according to claim 4 wherein the Fresnel microstructure mould is slidingly advanced in use to form the Fresnel microstructure.
6. The method according to claim 5, wherein the Fresnel microstructure mold is rotationally advanced while being slidably advanced, taking a set axis as a rotation center line, so as to form the coaxially arranged Fresnel microstructure, wherein the set axis is perpendicular to the base layer, and the length of the Fresnel microstructure mold extends along a radial direction of the rotation path.
7. A method according to any of claims 4-6, characterized in that the thickness of the layer to be processed is in the range of 10-100 μm.
8. The method of any one of claims 4-6, wherein the substrate layer has a light transmittance of 25% -90%.
9. An orthographic projection screen comprising a surface layer, a fresnel film sheet produced by the method according to any one of claims 4 to 8, and a light reflecting layer, which are sequentially stacked.
10. The front projection screen of claim 9, wherein the surface layer comprises an antireflection film.
11. The front projection screen of claim 10, wherein the antireflection film is provided with a plurality of layers, and the refractive index of the antireflection film near the fresnel film is greater than the refractive index of the antireflection film far from the fresnel film.
12. The front projection screen of any of claims 9-11, wherein the substrate layers comprise a first substrate layer and a second substrate layer, the first substrate layer disposed on a side of the second substrate layer away from the light reflecting layer; the second substrate layer has optical scattering particles distributed therein.
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