Cylindrical lens component and method for making, rear projection screen and back projection TV
Technical field
The present invention relates to optical technology, particularly the cylindrical lens component and the method for making of rear projection screen use.
Background technology
Rear projection screen is normally combined by Fresnel Lenses and cylindrical lens component, the general version of cylindrical lens component in the used screen of present three pipe CRT back projection TVs as shown in Figure 1, incident light passes through the column convex lens focus of the plane of incidence near the column convex lens center of exit facet, the zone line of adjacent column convex lens forms bossing on exit facet, at bossing printing black streaking, can guarantee that like this exit facet one side has the blacking of maximum area, thereby maximum possible improves contrast.
Along with universal day by day as the high definition projection TV of projection source of LCD, DLP, LCOS, being applied to has great demand on the screen market of this projection TV, the pixel of existing high definition projection TV has developed into present millions of pixels from several ten thousand pixels in the past, thereby (requiring at least less than 0.25mm) eliminates the Moire fringe that causes because of cylindrical mirror cycle and pixel period to require the pitch of cylindrical mirror meticulousr; But the pitch that in the past was applied to the cylindrical mirror of the cylindrical lens component in the used screen of three pipe CRT back projection TVs generally can not satisfy the requirement of present high definition projection TV greater than 0.5mm, pitch is very difficult toward little direction manufacturing again, because mentioning traditional cylindrical lens component incident light, the front passes through the column convex lens focus of the plane of incidence near the column convex lens center of exit facet, so it is thin more that the more little cylindrical lens component of pitch will be done, also high more to the relative positional accuracy requirement of front and back convex lens simultaneously, not so emergent light will be got to above the blackstreak.
In sum, the high definition projection TV requires to have pitch cylindrical lens component meticulousr and that can form black streaking in correct position to match.
Summary of the invention
Technical matters to be solved by this invention is, a kind of cylindrical lens component and preparation method thereof is provided, and described cylindrical lens component can be realized high resolution, high-contrast.
The present invention also provides a kind of rear projection screen and back projection TV that adopts aforementioned cylindrical lens component.
The technical scheme that the present invention solve the technical problem employing is, provides a kind of cylindrical mirror group to comprise cylindrical lens array and light absorption striped, in the surface coverage of cylindrical lens array transparent material arranged, and the refractive index of described transparent material is less than the refractive index of cylindrical mirror material.
Surface coverage at transparent material has another kind of material, and described light absorption striped is a black streaking, and described black streaking is on the cladding material between adjacent two cylindrical mirrors.Distance between adjacent two black streakings is not more than 0.25mm.
The shape of described cylindrical mirror satisfies following relation:
Suppose that final projection luminous energy is f (θ) at spatially distributed functions, the spatially distributed functions of projection luminous energy after the cylindrical mirror diffusion is f
1(θ), the spatially distributed functions of projection luminous energy after the diffusion layer diffusion is f
2(θ),
F (θ) equals f
1(θ) and f
2Convolution (θ).
Satisfy following relation between the shape of the refractive index of the material of cylindrical mirror, the refractive index of transparent material and cylindrical mirror:
N33/N34<Sin(Ac);
N33/N34>Sin(At);
Wherein, N33 is the refractive index of the transparent material of low-refraction, N34 is the refractive index of cylindrical mirror array material, Ac is the incident angle that projection ray gets to the cylindrical mirror side, and At is projection ray and gets to the incident angle of the projection ray of cylindrical mirror side through being totally reflected to the cylindrical mirror top at the cylindrical mirror top.
Described cylindrical lens array is the photocuring moulding or is hot-forming.Described transparent material is photo-curing material, thermosetting material or thermoplastic.The non-exiting surface zone of light absorption striped between adjacent two cylindrical mirrors.Under cylindrical lens array, also has transparent sheet.
On the described cylindrical lens array or under also have scattering layer, described scattering layer contains scattering particle.
The present invention also provides a kind of rear projection screen, constitute by cylindrical lens component and Fresnel Lenses, described cylindrical lens component comprises cylindrical lens array and light absorption striped, it is characterized in that, surface coverage at cylindrical lens array has transparent material, and the refractive index of described transparent material is less than the refractive index of cylindrical mirror material; The surface coverage of the transparent material between adjacent two cylindrical mirrors has first material, and described light absorption striped is a black streaking, and described black streaking is on the cladding material between adjacent two cylindrical mirrors.Described first material is light binding or conducting material.
The present invention also provides a kind of back projection TV, screen is made of cylindrical lens component and Fresnel Lenses, described cylindrical lens component comprises cylindrical lens array and light absorption striped, described cylindrical lens component comprises cylindrical lens array and light absorption striped, surface coverage at cylindrical lens array has transparent material, and the refractive index of described transparent material is less than the refractive index of cylindrical mirror material; The surface coverage of the transparent material between adjacent two cylindrical mirrors has first material, and described light absorption striped is a black streaking, and described black streaking is on first material between adjacent two cylindrical mirrors.
The present invention also provides a kind of method of making cylindrical lens component, may further comprise the steps:
A. apply optic-solidified adhesive on transparent sheet, roll on the cylindrical mirror mould roller through roller then, photocuring forms the cylindrical mirror array;
B. the good cylindrical mirror array that will be shaped is having dip-coating light binding or hot-setting adhesive in the groove of transparency liquid of low-refraction through the dip-coating roller, carry out photocuring or heat curing behind the levelling, forms the low-refraction hyaline layer on the surface of cylindrical mirror array;
C. at surface coverage first material of transparent material, the surface of the packing material between the adjacent cylindrical mirror forms black streaking, makes the thin slice that has black streaking;
D. thin slice and the scattering layer that step c is made is bonding.
Described step c comprises:
C1) at the surface coverage photo-curing material of transparent material;
C2) with the below irradiates light curing materials of ultraviolet light, expose from the cylindrical mirror array;
C3) spray black powder in a side that scribbles photo-curing material, make part be stained with black powder with viscosity.
Described step c2) in, described ultraviolet ray is perpendicular to the bottom surface of cylindrical lens array.
Described step c1) in, by pull, spraying coating process, at the surface coverage photo-curing material of the transparent material of low-refraction.
The black powder that sprays is carbon dust or black magnetic powder.
The invention has the beneficial effects as follows, cylindrical lens component that the present invention proposes and Fresnel Lenses are combined to form and are applied to the rear projection screen as the high definition projection TV of projection source with LCD, DLP, LCOS, the characteristics of this cylindrical lens component are to utilize light in the side of cylindrical mirror unit total reflection to take place to penetrate from top, cylindrical mirror unit, realize high-contrast thereby form black streaking at non-outgoing area.The purpose of this concrete invention provides a kind of high resolution, the cylindrical lens component that is applicable to the high definition rear-projection TV of high-contrast, and at the tram of cylindrical lens component formation black streaking, the striped of this cylindrical mirror is meticulousr.
The present invention is further illustrated below in conjunction with the drawings and specific embodiments.
Description of drawings
Fig. 1 is that a kind of tradition is applied to the general version synoptic diagram of cylindrical lens component in the used screen of three pipe CRT back projection TVs.101 is black streaking.
Fig. 2 is a kind of structural drawing that is applied to the core thin slice of cylindrical lens component that this patent proposes.Among the figure 31: black streaking (carbon black or black magnetic etc.), 32: light binding or conducting material, 33: light binding or other low-refraction transparent materials, 34: the transparent material of light binding or other highs index of refraction, 30: transparent membrane (PET or PC or PS or BOPP or PVC etc.).
Fig. 3 is in the cylindrical lens component of the present invention, the optical relation synoptic diagram between projection ray and the cylindrical mirror.
Fig. 4 is a kind of cylindrical lens component structural representation that this patent proposes.Among the figure 11: meticulous hair side, 12: scattering diluent, the scattering layer (baseplate material can be selected MBS or MS or PMMA etc.) of 10:MBS or MS or PMMA band scattering diluent and meticulous hair side, 20: tackifier (optics adhesive sticker (pressure sensitive adhesive) or light binding etc.); The introduction and the explanation referring to Fig. 2 of other symbols.
Fig. 5 is the another kind of cylindrical lens component structural representation that this patent proposes.Wherein various symbols are referring to introduction and the explanation of Fig. 3.
Fig. 6 is the first step that proposes in this patent in the manufacture method of this cylindrical lens component: the shaping structures of cylindrical mirror array.P11 wherein: transparent membrane, P12: nip rolls, P13: light binding; P14: scraper, P15: nip rolls, P16: the film that has uncured light binding; P17: hold-down roller; P18: mould roller, P19: ultraviolet source, P20: demoulding roller; P21: diaphragm; P23: pad pasting roller, P24: hold-down roller, P25: semi-manufacture rolling.
Fig. 7 is the cylindrical mirror array synoptic diagram that the first step forms in the manufacture method.
Fig. 8 is second step that proposes in this patent in the manufacture method of this cylindrical lens component: the film of giving plating low-refraction on the structure of forming.P26 wherein: go up the operation semi-manufacture, P27: diaphragm wind-up roll, P28: stripper roll, P29: dip-coating rod, P30: light binding groove, P31: nip rolls, P32: uviol lamp, P33: diaphragm, P34: hold-down roller, P35: hold-down roller, P36: semi-manufacture rolling.
Fig. 9 is the structural representation after cylindrical mirror array surface is coated with the low-refraction transparent material that second step obtained in the manufacture method.
Figure 10 is the 3rd step that proposes in this patent in the manufacture method of this cylindrical lens component: form black streaking.P37 wherein: go up the operation semi-manufacture, P38: diaphragm wind-up roll, P39: stripper roll; P40: dip roller, P41: light binding, P42: nip rolls; P43: the uv-exposure lamp, P44: the also exposure behind the gluing, the product that the adhesion property of light binding changes is seen Figure 11; P45: ink fountain, P46: regelate uviol lamp, P47: remove device for ink; P48: (viscosity is good for diaphragm; do not shift), P49: hold-down roller, P50: hold-down roller; P51: diaphragm wind-up roll; P52: stripper roll, P53: hold-down roller, P54: (viscosity is good for tacky film; do not shift); P55: hold-down roller, P56: hold-down roller, P57: semi-manufacture rolling.
Thereby Figure 11 solidifies the light binding at cylindrical mirror top and other parts are not solidified the explanation that forms attachment zone and non-attachment zone on the light binding surface at the ultraviolet photoetching perpendicular to transparent sheet that cylindrical mirror sends through uviol lamp with respect to the opposite side of transparent sheet.201 is non-attachment zone, and 202 is attachment zone.
Figure 12 is the core thin slice synoptic diagram of the present specification that the 3rd step obtained in the manufacture method.
Figure 13 is the 4th one that proposes in this patent in the manufacture method of this cylindrical lens component: final molding.P58 wherein: go up the operation semi-manufacture, P59: stripper roll, P60: diaphragm wind-up roll; P61: dip-coating rod; P62: adhesive sticker (pressure sensitive adhesive) groove, P63: smoothing roller, P64: nip rolls; P65: infrared lamp; P66: band hair side and scattering diluent scattering layer, P67: pressure roll, P68: pressure roll; P69: cutoff tool, P70: carrying roller.
Embodiment
Embodiment about cylindrical lens component of the present invention is as follows.For ease of understanding, in the present embodiment, be example with Fig. 2, the direction of cylindrical mirror cambered surface is defined as the top, the direction on cylindrical mirror plane is defined as the below, the lower surface of cylindrical lens array is called the bottom surface of cylindrical lens array.Thus, in exposure process, ultraviolet ray is shone from bottom to top, and in actual the use, the light of projection TV is injected cylindrical mirror from the below, penetrates from the cylindrical mirror top then, penetrates from the top in other words.
Embodiment 1:
Referring to Fig. 2, in the surface coverage of cylindrical lens array 34 transparent material 33 is arranged, the refractive index of described transparent material 33 is less than the refractive index of cylindrical mirror material.Be filled with coating material 32 between adjacent two cylindrical mirrors, described light absorption striped 31 is a black streaking, and described black streaking is between adjacent two cylindrical mirrors, on the coating material 32, and the distance between adjacent two black streakings is not more than 0.25mm.Described coating material 32 is light binding or conducting material.
Below cylindrical lens array 34, also be bonded with transparent sheet (30).As the unit that constitutes cylindrical lens array, the shape of cylindrical mirror satisfies following relation:
Suppose that final projection luminous energy is f (θ) at spatially distributed functions, projection luminous energy is through cylindrical mirror
Spatially distributed functions after the diffusion is f
1(θ), the spatially distributed functions of projection luminous energy after the diffusion layer diffusion is f
2(θ),
Be that f (θ) equals f
1(θ) and f
2Convolution (θ).
And, satisfy following relation between the refractive index of the refractive index of the material of cylindrical mirror, transparent material 33 and the shape of cylindrical mirror:
N33/N34<Sin(Ac);
N33/N34>Sin(At);
Wherein, N33 is the refractive index of the transparent material of low-refraction, N34 is the refractive index of cylindrical mirror array material, Ac is the incident angle that projection ray gets to the cylindrical mirror side, and At is projection ray and gets to the incident angle of the projection ray of cylindrical mirror side through being totally reflected to the cylindrical mirror top at the cylindrical mirror top.As shown in Figure 3.
Cylindrical lens array 34 is the photocuring moulding, and described transparent material 33 is a photo-curing material.Perhaps, described cylindrical lens array 34 also can be for hot-forming, and described transparent material 33 is thermosetting material or thermoplastic.
Embodiment 2:
Referring to Fig. 4, the difference of present embodiment and embodiment 1 is, above cylindrical lens array 34 and black streaking 31, and also bonding scattering layer 10, described scattering layer 10 contains organic scattering particle 12.
Embodiment 3:
The difference of present embodiment and embodiment 1 is, is distributed with organic scattering particle 12 in transparent material 33.Also have one deck dielectric layer on the cylindrical lens array 34, the surface of described dielectric layer is meticulous hair side.Also can plate the deielectric-coating of low reflection on the surface of described dielectric layer 10.
Embodiment 4:
Referring to Fig. 5.The difference of present embodiment and embodiment 1 is, below transparent sheet 30, also use tackifier 20 bonding scattering layer 10, described scattering layer 10 contains organic scattering particle 12.The lower surface of described scattering layer 10 also has one deck dielectric layer, and the surface of described dielectric layer is meticulous hair side.
Produce this cylindrical lens component and can adopt following technology:
The first step: the shaping structures of cylindrical mirror array
Describe as Fig. 6, transparent sheet P11 is coated with photocuring glue P13 in a side of transparent sheet after the P12 nip rolls flattens, and through scraper P14 optic-solidified adhesive is scraped uniformly to be put on the transparent sheet; The transparent sheet that has light binding is fitted through hold-down roller P17 and cylindrical mirror mould roller P18, makes light binding fill up the striped of cylindrical mirror drum die; Send ultraviolet ray with uviol lamp and penetrate transparent sheet irradiation light binding, light binding is solidificated on the transparent sheet, so just formed the cylindrical mirror array with the mould complementation, as shown in Figure 7; Through the demoulding roller P20 demoulding, the demoulding is after pad pasting roller P23 and pressing bar P24 are attached to diaphragm P21 on the cylindrical mirror array surface of forming again; Rolling is semi-manufacture P25 behind the pad pasting, just descends the semi-manufacture P26 of operation.
Above-mentioned transparent sheet can be selected the strong PET of ultraviolet light handling capacity, PC, PS, thin slices such as BOPP, PVC.
Second step: the film of giving plating low-refraction on the structure of forming.
Describe as Fig. 8, last operation semi-manufacture P26 peels off through the diaphragm that stripper roll P28 will go up operation; Through dip-coating roller P29 dip-coating light binding in light binding groove P30; Through nip rolls P31 pull levelling; Form low-index layer through uviol lamp P32 photocuring on cylindrical mirror array surface, as shown in Figure 9; Rolling is semi-manufacture P36 after hold-down roller P34 and P35 are attached to diaphragm P33 on the surface of the cylindrical mirror array that is coated with low-refraction again, just descends the P37 of operation.
Above-mentioned coating process also can take light binding is sprayed to the technology on cylindrical mirror array surface.
The 3rd step: form black streaking
As Figure 10, last operation semi-manufacture P37 peels off through the diaphragm that stripper roll P39 will go up operation; Through dip-coating roller P40 dip-coating light binding in light binding groove P41; Through nip rolls P42 pull levelling; Thereby the light binding at cylindrical mirror top is solidified and other parts do not take place to solidify and form attachment zone and non-attachment zone (seeing Figure 11) on the light binding surface at the ultraviolet photoetching that cylindrical mirror sends through uviol lamp P43 with respect to the opposite side of transparent sheet perpendicular to transparent sheet; Ink powder under ink fountain P45 again; Uviol lamp P46 through sending spuious ultraviolet light solidifies uncured light binding again, makes to be spread across uncured light binding and ink powder firmly bonds; To remove formation black streaking (seeing Figure 12) less than most of ink powder of bonding through removing device for ink P47 again; Tacky film P48 is attached to the one side of spilling ink powder through hold-down roller P49 and P50 again; Through stripper roll P52 and hold-down roller P53 tacky film is stripped down again, the ink powder that does not bond is removed completely; Rolling is semi-manufacture P57 after hold-down roller P55 and P56 are attached to diaphragm P54 on the surface of the cylindrical mirror array that forms black streaking again, just descends the P58 of operation.
The 4th step: final molding
Describe as Figure 13, last operation semi-manufacture P58 peels off through the diaphragm that stripper roll P59 will go up operation; Transparent non-setting adhesive (pressure sensitive adhesive) through dip-coating roller P61 dip-coating in adhesive sticker (pressure sensitive adhesive) groove P62; Again through a pair of smoothing roller P63 with adhesive sticker (pressure sensitive adhesive) flattening-out, through infrared lamp P65 the solvent and the low molecular weight substance of adhesive sticker (pressure sensitive adhesive) are toasted away again; Scattering layer P66 is bonded together scattering layer and the transparent sheet that has cylindrical mirror array and black streaking through pressure roll P67, P68; The transparent sheet that will have cylindrical mirror array and a black streaking at the interval of scattering layer with cutoff tool P69 cuts off again, like this with regard to complete formation cylindrical lens component (see figure 2) of the present invention.
The simple description of the production technology of the cylindrical lens component that production technology described above just proposes this patent, practitioner that this is professional or relevant speciality personnel can do many changes on production technology that this patent proposes and method:
Optic-solidified adhesive as the 3rd step in the technology of second low-refraction glue that goes on foot in the technology that this patent is proposed and this patent proposition unites two into one, just behind the intact low-refraction light binding of describing in second step of dip-coating and do not solidify and directly entered for the 3rd step, the ultraviolet photoetching perpendicular to transparent sheet that sends through uviol lamp with respect to the opposite side of transparent sheet at cylindrical mirror solidifies the light binding of cylindrical mirror top low-refraction and other parts are not solidified, thereby forms attachment zone and non-attachment zone (seeing Figure 11) on the light binding surface.
Mention dip-coating pull plated film as many places in the production technology of this patent description, can become spraying levelling plated film.
The pull plating low-refraction transparent material technology of describing as this patent also can adopt the inorganic material of method plating one deck low-refractions such as magnetron sputtering or evaporation sputter to replace.