JP2002116504A - Fiber screen and method of manufacturing fiber screen - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a fiber screen which can be manufactured with good productivity at a low cost and a method of manufacturing the fiber screen. SOLUTION: The fiber screen manufactured in the following manner and the method for manufacturing the same are provided: while a piece of fiber 18 is aligned at a pitch approximately equal to the diameter of the fiber, the fiber is wound around a drum 11 and is adhered linearly in a direction approximately perpendicular to the winding direction and the center of adhered segments is cut open, by which a fiber sheet 3 is formed. The curling of the fiber sheet 3 is removed by heating and thereafter the fiber sheet 3 and a film is installed in a casing and the inside of the casing is made nearly vacuum by sucking air therefrom and is heated by a heater. Hydrostatic pressure is then applied to both to tightly transfer the film to the fiber sheet 3 without impairing the rugged shape of its surface.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber screen in which fibers are arranged at a pitch substantially equal to the diameter of the fibers, and a method of manufacturing a fiber screen.

[0002]

2. Description of the Related Art Various types of screens have been proposed for displaying an image projected by an image projection apparatus so that the image can be observed. It is roughly classified into a transmission type screen that enables observation.

[0003] Among these, there are various types of transmissive screens in which various measures such as arranging beads are devised in order to increase light emission luminance.
JP-A-7377 discloses a screen in which fibers are arranged.

More specifically, the transmissive screen described in Japanese Patent Publication No. 8-7377 is a transmissive screen in which a number of plastic translucent strands are arranged in parallel to form a sheet. The translucent strands are fused and formed into a sheet by forming a fusion surface on the outer surface of each adjacent strand, and a single or plural sheets form a screen body. Have been.

[0005]

However, it is technically difficult to align a large number of strands after ejection with the technique disclosed in Japanese Patent Publication No. H8-7377, and moreover, to dispose each strand on the outer surface. Although they are fused together and integrated, it is difficult to completely fuse them so that they are actually uniform.

[0006] Therefore, it is desired to realize a technique capable of producing a high-quality fiber screen having fibers arranged at a high productivity at a low cost.

The present invention has been made in view of the above circumstances, and has as its object to provide a high quality fiber screen and a method of manufacturing a fiber screen which can be manufactured with good productivity at low cost.

[0008]

In order to achieve the above object, a fiber screen manufacturing method according to a first aspect of the present invention provides a method of manufacturing a fiber screen by aligning a single fiber with a pitch substantially equal to the diameter of the fiber. Winding, and a step of linearly bonding the fiber wound around the winding member in a direction substantially perpendicular to the winding direction, and substantially centering the linearly bonded portion of the fiber wound around the winding member. Forming a fiber sheet by cutting, thereby producing a fiber screen provided with the fiber sheet.

The fiber screen manufacturing method according to a second aspect of the present invention is the fiber screen manufacturing method according to the first aspect, wherein the winding member is rotated by a rotary drive source, and the fiber member is rotated by the rotary drive source. A step of reducing the driving force from the rotary drive source by a speed reducer so as to synchronize with the winding member, and driving the guide frame by a driving force synchronized with the rotation of the winding member transmitted from the speed reducer. And a step of sending out the fiber while moving the fiber guide such that the fiber is wound around the winding member at a pitch substantially equal to the diameter of the fiber while receiving the driving force while being guided by the guide frame,
Is further provided.

Further, in a fiber screen manufacturing method according to a third aspect of the present invention, in the fiber screen manufacturing method according to the second aspect, the winding member has a cylindrical shape or a cylindrical shape, and has a cylindrical central axis or a cylindrical shape on a peripheral surface thereof. A drum having a groove formed in parallel with the central axis, wherein the bonding step and the cutting step are performed along the groove.

A fiber screen manufacturing method according to a fourth invention is the fiber screen manufacturing method according to the second invention, wherein the winding members are arranged so as to be substantially parallel to each other at a predetermined distance. Characterized by having a rod-shaped member.

A fiber screen manufacturing method according to a fifth aspect of the present invention is the fiber screen manufacturing method according to the second aspect, wherein the fiber sheet is heated to a temperature lower by 50 ° C. than the glass dislocation temperature. (A temperature lower than the temperature by 10 ° C.) or less, and a step of flattening by heating at a temperature of not more than.

In the fiber screen manufacturing method according to the sixth aspect of the present invention, the plurality of fibers are arranged in a plane so as to exhibit an uneven pattern whose surface shape is periodically repeated at a predetermined pitch. A step of closely transferring a film to the fiber sheet along the surface shape.

A fiber screen manufacturing method according to a seventh invention is the fiber screen manufacturing method according to the sixth invention, wherein the step of fixing the fiber sheet and the film on the stage, the step of housing the stage in a housing, The method further includes a step of drawing air from the housing by a vacuum pump to bring the vicinity of the fiber sheet and the film closer to a vacuum, and a step of heating the inside of the housing by a heater.

In a fiber screen manufacturing method according to an eighth aspect, in the fiber screen manufacturing method according to the sixth aspect, the step of closely transferring the film is performed.
With an object that can abut against the object with hydrostatic pressure,
It is performed by pressing the film against the fiber.

According to a ninth aspect of the present invention, there is provided a fiber screen manufacturing method according to the eighth aspect, wherein the object which can be brought into contact with the hydrostatic pressure is:
It is a low-hardness elastic member or a gas or liquid sealed by an elastic seal member.

In a fiber screen manufacturing method according to a tenth aspect of the present invention, in the fiber screen manufacturing method according to the sixth aspect of the present invention, the step of closely transferring the film comprises forming an uneven pattern periodically repeated at a predetermined pitch of the fiber sheet. The pressing is performed by pressing a pressing member provided with a pressing surface having a shape corresponding to the above-mentioned method against the fiber sheet from above the film.

According to an eleventh aspect of the present invention, in the fiber screen manufacturing method according to the tenth aspect, the pressing member is a member having a columnar or cylindrical shape, and the fiber sheet is formed on a peripheral surface thereof. A shape corresponding to an uneven pattern that is periodically repeated at a predetermined pitch.

A fiber screen according to a twelfth invention is a fiber screen manufactured by using the fiber screen manufacturing method according to the sixth invention, wherein the film constituting the fiber screen is made of polyvinyl chloride, polyethylene, or polyimide. , Ethylene-vinyl-alcohol, acrylic-based, epoxy-based or polyimide-based resist material, or silicon-based resin. Among them, the most preferable are epoxy-based and polyimide-based resist materials because of their high transparency and soft hardness.

A fiber screen according to a thirteenth aspect is a fiber screen manufactured by using the fiber screen manufacturing method according to the sixth aspect, wherein a film constituting the fiber screen comprises a film base and a film base. And an adhesive layer formed on the surface in contact with the fiber sheet.

A fiber screen according to a fourteenth invention is characterized in that, in the fiber screen according to the thirteenth invention, the adhesive layer is made of a hot melt adhesive.

A fiber screen according to a fifteenth aspect of the present invention is manufactured by using the fiber sheet manufactured by the method of manufacturing a fiber screen according to the first aspect of the invention, and by using the fiber screen manufacturing method of the sixth aspect of the invention. Characterized in that fibers which are not directly bonded except for both end portions are indirectly fixed to each other by transferring the film onto a fiber sheet surface in close contact with the fiber screen.

A fiber screen according to a sixteenth aspect of the present invention is a fiber screen manufactured by using the fiber screen manufacturing method according to the sixth aspect of the present invention, wherein a film constituting the fiber screen is formed by laminating a plurality of film bases. It is characterized by the following.

In a fiber screen according to a seventeenth aspect, a first fiber group in which a plurality of fibers having a substantially circular cross section is arranged in one direction and a plurality of fibers having a substantially circular cross section intersect the one direction. And a second group of fibers alternately woven in the other direction.

The fiber screen according to an eighteenth aspect of the present invention is the fiber screen according to the seventeenth aspect, wherein the fibers constituting the first fiber group and the fibers constituting the second fiber group have different diameters. It is characterized by being different.

According to a nineteenth aspect, in the fiber screen according to the seventeenth aspect, the weaving ratio between the first fiber group and the second fiber group is 1: 1. .

The fiber screen according to a twentieth aspect is the fiber screen according to the seventeenth aspect, wherein the weaving ratio between the first fiber group and the second fiber group is m: n (where m and n are relatively prime). (Except when m = n = 1).

[0028]

Embodiments of the present invention will be described below with reference to the drawings. FIGS. 1 to 10 show a first embodiment of the present invention. FIG. 1 is a front view and a side view showing an example of a configuration of a fiber winding device for winding a fiber around a winding member. It is the front view and side view which show the other structural examples of the fiber winding device which winds a fiber around a winding member.

In the method of manufacturing a fiber screen according to the present embodiment, a fiber sheet is formed by winding a fiber around a winding member and then cut, and the fiber sheet is formed by sandwiching the fiber sheet with a film.

First, referring to FIGS. 1 and 2, a description will be given of a configuration in which a fiber is wound to form a fiber sheet.

The example shown in FIG. 1 uses a cylindrical (or cylindrical) drum as a winding member.

In this fiber winding device, a drum 11 as a winding member having a cylindrical shape (or a cylindrical shape) is held so as to be rotatable around the central axis of the cylinder or the central axis of the cylinder. As shown in FIG. 1A, a groove 11b parallel to the rotation axis is formed in the surface 11a.

On one side surface of the drum 11, a cylindrical portion 11c for receiving a driving force is provided so as to protrude therefrom.
The belt 13 is hung.

As shown in FIG. 1B, the belt 13 is connected to a motor 12 which is a driving source for rotation, and the belt 13 is driven by the rotation of the motor 12, so that the drum 11 Is rotated.

Another belt 15 is hung on the motor 12, and the other belt 15 is hung on a speed reducer 14. The speed reducer 14 adjusts the rotation speed of a later-described guide frame 16 so that the pitch of the fiber 18 wound by the rotation of the drum 11 becomes substantially equal to the diameter of the fiber 18, This is for synchronizing the movement of 17.

The rotation decelerated by the speed reducer 14 is transmitted to the guide frame 16. The guide frame 16 is, for example, a feed screw shaft having a thread engraved on a peripheral surface thereof, and a threaded portion formed on the fiber guide 17 is screwed.

When the supplied fiber 18 is wound around the drum 11, the fiber guide 17 guides the fiber 18 in order to define a winding position in the rotation axis direction, and meshes with the guide frame 16. A thread portion for guiding the fiber 18, a ring portion for guiding the fiber 18,
Is configured.

In the example shown in FIG. 2, two rod bars are used as winding members.

That is, the winding member 19 in the example shown in FIG. 2 is composed of two rod-shaped rod bars 19a, as shown in FIG. 2A, and these rod bars 19a are parallel to each other at a predetermined distance. A pair of support portions 19b (see also FIG. 2 (B)) which are respectively held at both end surfaces so that the driving force is applied from the belt 13 attached to a substantially central portion of one of the support portions 19b. And a cylindrical portion 19c for receiving the cylindrical portion 19c, and is held so as to be rotatable around the central axis of the cylindrical portion 19c.

Although the winding member is constituted by two rod bars here, the winding member may be constituted by three or more rod bars.

When a fiber sheet is formed using the fiber winding device having such a configuration, the following operation is performed. Here, the configuration of FIG. 1 is specifically described as an example, but the configuration of FIG. 2 can be performed in substantially the same manner.

First, the fiber winding device is set to an initial state. In this initial state, the fiber guide 17 is in contact with a predetermined initial position on the speed reducer 14 side. In this state, the fiber 18 made of glass or plastic is inserted through the fiber guide 17.
Of the cylindrical portion 11 on the peripheral surface 11a of the drum 11
Fix to the c-side end.

Thereafter, when the motor 12 is rotated clockwise in FIG. 1B, the rotating power is transmitted to the cylindrical portion 11c via the belt 13, and the drum 11 starts rotating. Thus, the fiber 18 starts to be wound along the peripheral surface of the drum 11.

At the same time, the driving force of the motor 12 is transmitted to the speed reducer 14 via the belt 15 and the speed reducer 1
4, the guide frame 1
6 rotates. Then, the fiber guide 17 meshing with the guide frame 16 starts to move in a direction away from the speed reducer 14. Fiber guide 1 at this time
The moving speed of the drum 7 is such that the drum 11 moves along the guide frame 16 by the diameter of the fiber 18 each time the drum 11 makes one rotation.
The fiber 18 can be wound around 1a without gaps and without overlapping.

In this way, when the fiber guide 17 comes into contact with the predetermined end position on the distal end side of the guide frame 16, the motor 12 is stopped, and the winding step is completed. The following steps will be described with reference to FIG.

FIG. 3 is a view showing a process of preparing a fiber sheet by expanding the fiber wound on the drum.

At the end of the above winding step, FIG.
As shown in FIG.
Are wound at a pitch equal to the diameter of the fiber 18 without any gap.

In this state, a linear adhesive is applied to the fiber 18 located at the position corresponding to the groove 11b, so that the direction perpendicular to the winding direction as shown in FIG. Is formed.

When the bonding step is completed and fixed, the center of the linear bonding portion 10 of the fiber 18 wound around the drum 11 is substantially aligned with the groove 11b as shown in FIG. Cut along. At this time, since the groove 11b is formed as described above and cut along the groove 11b, the peripheral surface 11a of the drum 11 is not damaged by the cutting operation. .

After the above cutting step is completed, as shown in FIG. 4D, a developing step is performed to form a substantially planar fiber sheet 3.

The fiber sheet 3 thus formed can be understood from the above-described manufacturing process.
Adjacent fibers 18 are bonded only at both ends by bonding portions 10a and 10b obtained by dividing the bonding portion 10, and are not directly bonded at other portions.

As described above, the drum 11 and the rod bar 19a
In many cases, the fiber sheet 3 formed by being wound around a winding member, for example, has a winding habit and is still curved by simply being expanded.

Therefore, after the development, a treatment such as heating is performed to remove the curl and to improve the flatness.

That is, the fiber sheet 3 is heated to a temperature at which an annealing effect occurs (annealing temperature). This alleviates the internal stress that has caused the curl and flattens the fiber sheet 3.

When the fiber sheet 3 has been flattened, the fiber sheet 3 is returned to normal temperature, whereby the fiber sheet 3 having a curl can be obtained.

Since the annealing temperature is generally (a temperature 30 ° C. lower than the glass transition temperature), the temperature for removing the winding habit is about the annealing temperature ± 20 ° C., that is, (the glass transition temperature). The heating may be performed at a temperature of not less than 50 ° C. with respect to the temperature and not more than (temperature lower by 10 ° C. with respect to the glass transition temperature).

As an example, in the case of acrylic, about 110
Since ℃ is the glass transition temperature, the annealing temperature is about 80 ℃. Therefore, for a fiber sheet formed using acrylic fiber, a temperature of 60 ° C.
What is necessary is to heat so that it may become the temperature of about 0 degreeC.

Next, a step of closely transferring the film to the flat fiber sheet 3 thus formed is performed.

An example of the structure for performing the film transfer will be described with reference to FIGS. FIG. 4 is a view showing the entire structure of closely transferring a film to a fiber sheet using a compressed gas or liquid, and FIG. 5 is a sectional view showing the internal structure of the film transfer apparatus in FIG.

As shown in FIG. 5, in the film transfer device 21, the inside of the housing 31 has an upper first chamber 31a, a lower second chamber 31b, and the first chamber 31a and the second chamber 31b. And a third chamber 31c in which the fiber sheet 3 and the film 4 are set. The third chamber 31c is airtight or watertight with respect to the first chamber 31a and the second chamber 31b. It is configured to be.

In such a configuration, as shown in FIG. 4, the first chamber 31a and the second chamber 31b are
The gas or liquid compressed from the supply device 22 is supplied to the supply pipe 2
4, while the air inside the third chamber 31 c is sucked by the vacuum pump 23 through the exhaust pipe 25 to approximate the vacuum.

Referring to FIG. 5, the structure of the film transfer device 21 will be described again.

The film transfer device 21 has a box-shaped housing 31, and a partition wall 32 for ensuring airtightness or watertightness is protruded downward from the upper side inside the housing 31. Also, the partition wall 32 protrudes upward.

On the lower end surface of the partition wall 32 protruding from the upper side, there is a sealing member which can press the film 4 elastically while ensuring airtightness or watertightness in the first chamber 31a. A membrane member 33 is provided;
Similarly, a film member 33 for the second chamber 31b is provided on the upper end surface of the partition wall 32 protruding from the lower side.

As described above, inside the first chamber 31a and the second chamber 31b, which are respectively surrounded by the partition wall 32 and the membrane member 33, a heater 3 for increasing the ambient temperature and heating.
4 is attached.

Further, the first chamber 31a and the second chamber 31b
Are formed with openings 31d and 31e for flowing gas or liquid from the supply pipe 24, respectively, while the third chamber 31c is formed with an opening for communicating with the exhaust pipe 25 and discharging air. 31f is formed.

A stage 35 for mounting the fiber sheet 3 and the film 4 via the film member 33 is provided near the lower side of the film member 33 in the second chamber 31b.

Then, the first chamber 3 in the third chamber 31c
While the fiber sheet 3 is set at a position between the film member 33 of 1a and the film member 33 of the second chamber 31b,
The film 4 is set so as to sandwich both sides of the fiber sheet 3.

In such a configuration, when the film 4 is closely transferred to the fiber sheet 3, the following operation is performed.

As described above, the fiber sheet 3 and the two films 4 are placed on the stage 35 with the film member 33 interposed therebetween.
Is placed, first, the third pump is
The air in the chamber 31c is sucked to make it as close to a vacuum state as possible.

Next, the film 34 is softened by energizing the heater 34 to increase the ambient temperature in the first chamber 31a and the second chamber 31b.

Thereafter, gas or liquid is injected from the supply device 22 into the first chamber 31a and the second chamber 31b and pressurized, whereby the membrane member 33 expands and the film 4 is applied to the fiber sheet 3. And press. The pressure at this time is a pressure substantially equal to the hydrostatic pressure because the film member 33 has sufficient flexibility and elasticity.

As a result, the film 4 is transferred to both sides of the fiber sheet 3 in close contact with each other. At this time, since the air in the third chamber 31c has been removed as described above, the fiber sheet 3 and the film 4 There is no air layer between the two.

Here, the close contact transfer means the following.

That is, as described above, the fiber sheet 3 has a configuration in which the plurality of fibers 18 are arranged in parallel without any gap, and thus the surface shape is configured by a plurality of cylindrical surfaces. Has a surface shape in which irregularities are repeated at a predetermined pitch. By adhering the film 4 along the periodic irregular shape of the surface of the fiber sheet 3, the surface shape when the film 4 is adhered is also formed so that the substantially cylindrical surface is similarly continuous. Means

The transfer of the film 4 to the surface of the fiber sheet 3 in close contact with the fiber 18 is simultaneously performed by indirectly fixing the fibers 18 which are not directly bonded except for both ends as described above. Has become.

Although a gas or a liquid is used in the above description, the present invention is not limited to this, and a low-hardness elastic member having a gel shape such as silicon rubber may be used.

Next, with reference to FIGS. 6 and 7, a description will be given of a film transfer device 21A adopting another configuration. FIG. 6 is a cross-sectional view showing another example of the internal configuration of the film transfer device, and FIG. 7 is a cross-sectional view showing a state in which a film is closely transferred to a fiber sheet by a pressing plate having a corrugated portion.

This film transfer device 21A is configured to press the film 4 with a plate-shaped member instead of transferring the film 4 by applying hydrostatic pressure with gas or liquid.

That is, the pressing plate 36a is provided in the first chamber 31a.
However, a pressing plate 36b is disposed in the second chamber 31b,
The heater 34 is attached to these pressing plates 36a and 36b so as to perform heating.

The pressing plates 36a and 36b
In addition, on the surface on which the fiber sheet 3 is pressed, a corrugated portion 36c which is a pressing die corresponding to the surface shape after pressing as shown in FIG. 7 is formed.

The corrugated portion 36c has a pitch when the plurality of fibers 18 are arranged in parallel without any gap, and has a shape corresponding to a continuous cylindrical surface formed after the film 4 is closely transferred. Is provided.

In the above-described configuration, the pressing plate 3
6a and 36b are fitted to the inner wall surface of the partition wall 32 so as to be airtight and slidable so as to maintain the airtightness when the air in the third chamber 31c is sucked. ,
Instead of providing the airtightness to 36b itself, the film member 33 as described above may be provided.

As shown in FIG. 7, the film 4 used here includes a film base 4a and an adhesive layer 4b.
The surface of the adhesive layer 4b is in contact with the fiber sheet 3.

The film transfer device 21A having such a configuration
Accordingly, the operation when the film 4 is closely transferred to the fiber sheet 3 is substantially the same except that the pressing plates 36a and 36b are driven and pressed instead of feeding the gas or liquid by the supply device 22. is there.

Next, with reference to FIG. 8, a description will be given of a film transfer device 21B adopting still another configuration.
FIG. 8 is a sectional view showing still another example of the internal configuration of the film transfer device.

This film transfer device 21 B
By rotating the film 4 while pressing it, the film 4 is closely transferred to the surface of the fiber sheet 3.

That is, the film 4 and the fiber sheet 3 are sandwiched from above and below by a roller 37 via the film member 33, and the heater 34 is attached to the roller 37 so that the film 4 is It is designed to be heated and softened.

The roller 37 is rotatably supported by a support shaft 38, and a pressure for sandwiching the film 4 and the fiber sheet 3 is applied through the support shaft 38.

Further, the pair of rollers 37 sandwich the film 4 and the fiber sheet 3 via the film member 33, and are guided along the guide 39 when moving while rotating in that state. ing.

The roller 37 may have a circumferential surface similar to the corrugated portion 36c shown in FIG. 7 or a hydrostatic pressure having sufficient flexibility and elasticity. A material that can be added to the film 4 and the fiber sheet 3 may be used.

Further, the housing 31B is formed in a shape in which the first chamber and the second chamber are opened so as to allow the movement of the roller supported by the support shaft 38.

The film transfer device 21B having such a configuration
The operation when the film 4 is closely transferred to the fiber sheet 3 is substantially the same as that shown in FIGS. 5 and 6, and the roller is moved along the guide 39 while applying pressure by the support shaft 38. The only difference is that 37 is rotated from one end of the film 4 and the fiber sheet 3 to the other end so that the transfer is made in close contact.

Next, FIG. 9 is a perspective view and a sectional view showing an example of the structure of a film which is closely transferred to a fiber sheet.

The fiber sheet 3 as shown in FIG.
The film 4 is closely transferred to the fiber screen 1
9 (B), 9 (C), and 9 (D) show the respective configuration examples when the AA cross section is viewed after the formation.

First, FIG. 9B shows an example in which the film 4 closely transferred to the fiber sheet 3 is constituted only by the film base 4a, and the material forming the film base 4a is different from that of the fiber sheet 3. It is applied when it is easy to adhere.

Since the film 4 is closely transferred to the fiber sheet 3, the surface of the formed fiber screen 1 does not impair the surface shape of the fiber sheet 3, as shown in FIG. A portion 1a and a concave portion 1b are formed.

Next, FIG. 9C shows an example in which the film 4 is composed of the film base 4a and the adhesive layer 4b, and the film is closely transferred so that the surface of the adhesive layer 4b is in contact with the fiber sheet 3. You. The adhesive layer 4b may be made of, for example, a hot-melt adhesive. In this case, the step of heating when the film base 4a is softened can also serve as the step of melting and bonding the adhesive layer 4b. Become.

FIG. 9 (D) shows that the film 4
This is an example in which the film base 4a and the two adhesive layers 4b are alternately laminated, and the adhesive layer 4b which is one surface of the film 4 is disposed so as to be in contact with the fiber sheet 3. .

The film base 4a as described above
Is formed of, for example, polyvinyl chloride, polyethylene, polyimide, ethylene vinyl alcohol, acrylic, epoxy or polyimide resist material, or silicon resin.

The adhesive layer 4b is formed by applying an adhesive to the film base 4a in advance.

FIG. 10 is a diagram showing a state in which a light beam is diffused when it is incident on the fiber screen 1 formed by closely transferring the film 4 to the fiber sheet 3 as described above.

When a luminous flux is projected by a rear projection type image projection apparatus, for example, at a position off the center of the image, FIG.
A light beam in a slightly oblique direction as shown on the left side of FIG.

The incident light flux is diffused in the fiber screen 1 configured as described above so as to spread around the center line normal to the main surface of the fiber screen 1 as shown on the right side of FIG. Is done. Therefore, an image formed on the fiber screen 1 can be observed with a wide viewing angle.

The degree of diffusion of the light beam at this time can be adjusted by changing the material and diameter of the fiber 18 and the material and thickness of the film 4.

According to the first embodiment, a roll-shaped fiber sheet can be formed simply by winding the fiber screen around a winding member such as a drum or a rod bar, and the fiber sheet can be formed substantially perpendicularly to the winding direction. Since a planar fiber sheet can be easily formed only by bonding along a simple line and cutting the center thereof, it can be manufactured easily and with high productivity. In particular, the manufacturing process can be simplified, and high productivity can be ensured, as compared with a conventional example in which adjacent fibers are bonded to each other on all side surfaces.

Further, since the fiber guide is guided by the guide frame while being synchronized with the winding member using the speed reducer, the pitch for aligning the fibers can be accurately maintained, and a high-quality fiber screen can be obtained. Become.

Further, when a drum is used as the winding member, a groove is formed on the peripheral surface of the drum, and bonding and cutting are performed at the groove, so that the work can be easily performed. In addition, the peripheral surface of the drum is not damaged by the cutting operation.

Then, the fiber sheet is flattened by heating at a temperature not lower than (temperature lower than the glass transition point temperature by 50 ° C.) and not higher than (temperature lower than the glass transition point temperature by 10 ° C.). As a result, it is possible to reliably planarize even if there is a curl or the like.

Further, by arranging a plurality of fibers in a state of being arranged in a plane, a fiber sheet having a concavo-convex pattern whose surface shape is periodically repeated at a predetermined pitch is formed on the fiber sheet. Since the film is closely transferred along, the incident light beam can be diffused without damaging the surface irregularities. In addition, the optical performance of the fiber screen can be changed by appropriately adjusting the thickness and material of the film or by laminating the film.

Further, by closely transferring the film, the fibers which are not directly bonded except for both ends can be indirectly fixed to each other, and the effect of increasing the thickness of the fiber screen and reinforcing it can be obtained. can get.

By providing an adhesive layer on a film, even if adhesion is difficult with a film base alone,
It is possible to easily transfer the adhesive to the fiber sheet, and if a hot melt adhesive is used, the heating step of softening the film base can also serve as the step of melting the adhesive.

Further, when the film is closely transferred to the fiber sheet, the air is sucked so as to be close to a vacuum, so that the film can be closely transferred without mixing an air layer between the fiber sheet and the film. Thus, a high-quality fiber screen can be formed.

FIG. 11 to FIG. 14 show a second embodiment of the present invention. FIG. 11 is a perspective view and a side view showing a fiber sheet in which fibers are alternately woven vertically and horizontally one by one. FIG. 12 is a perspective view showing a fiber sheet formed by alternately weaving two fibers vertically and horizontally, and FIG. 13 is a fiber constituted by alternately weaving two fibers in one direction vertically and two fibers in the other direction. FIG. 14 is a perspective view showing a sheet, and FIG. 14 is a view showing a state of light diffusion when the fiber sheet of FIG. 11 is approximately modeled.

In the second embodiment, the first
The same components as those of the first embodiment are denoted by the same reference numerals, and description thereof will be omitted. Only different points will be mainly described.

A first example of a fiber sheet formed by alternately weaving the fibers 18 will be described with reference to FIG.

This fiber sheet 3A is shown in FIG.
As shown in FIG. 11 (B) and FIG. 11 (B), the vertical fiber group 18A and the horizontal fiber group 18B are
It is configured to be staggered alternately. That is, for example, the fiber 18 made of one glass or plastic in the vertical direction is replaced with the fiber 1 in the horizontal direction.
8, the crossing at the upper side and the crossing at the lower side are alternately repeated, and the horizontal fiber 18 is likewise vertically moved with respect to the vertical fiber 18. The intersection is made.

A vertical fiber group 18A and a horizontal fiber group 18B
When the above-described weaving is performed using the fibers 18 having the same diameter, a fiber sheet 3A whose optical properties are symmetrical in the vertical direction and the horizontal direction is configured. The optical performance does not change even when rotated by 90 ° around the vertical line.

Next, FIG. 12 shows a case where one fiber 18 in the example of FIG.
And two in each of the horizontal fiber groups 18B, and are similarly woven alternately vertically and horizontally to form the fiber sheet 3B.
B.

When such braiding is performed, the point where the optical properties are symmetrical in the vertical and horizontal directions is maintained, but the degree of diffusion of the light can be changed.

The number is not limited to two, and it is of course possible to change the number.

FIG. 13 shows a fiber sheet 3C formed by alternately weaving one fiber in one direction in the vertical and horizontal directions and two fibers in the other direction alternately. In the example shown in FIG. The horizontal fiber group 18B is composed of one fiber.

By performing such weaving, the optical properties in the vertical direction and the optical properties in the horizontal direction can be made different from each other. For example, the degree of diffusion of the light in the vertical direction and the optical property in the horizontal direction can be changed. The degree of diffusion can be different.

The weaving ratio for making the optical properties in the vertical and lateral directions different is not limited to 1: 2 or 2: 1, but may be 1: many or many: 1. Or, for example, many: many such as 2: 3, and generally m: n (where m and n are mutually prime integers of 1 or more and m = n = 1). Good.

Next, the manner of light diffusion by the fiber sheet of FIG. 11 will be described with reference to FIG. FIG. 14 shows a fiber sheet 3A ′ that is approximately modeled from the fiber sheet 3A having the structure as shown in FIG. 11B. FIG. 14 shows the calculated light diffusion when the refractive index of the fiber sheet 3A 'is 1.52.

As described above, when a light beam is projected by the rear projection type image projecting device, a light beam in a slightly oblique direction as shown on the left side of FIG. 14 is incident at a position off the center of the image.

Even when a light beam is obliquely incident on the fiber sheet 3A 'as described above, the outgoing light beam becomes a diverging light beam which spreads around the normal line on the main surface of the fiber sheet 3A' and becomes wide. It is configured to obtain a viewing angle.

Although the vertical fiber and the horizontal fiber have the same diameter in the above description, they may have different diameters. Thereby, the diffusivity in the vertical direction and the horizontal direction can be made different, and by further appropriately changing the diameter,
It is also possible to control the diffusion angle.

Although the fiber sheet formed by knitting as described above may be used as it is as a fiber screen, as in the first embodiment described above, a film is closely transferred to both surfaces to form a fiber screen. Needless to say, it may be configured.

According to the second embodiment, the same effects as those of the first embodiment can be obtained, and the fiber sheet is formed by weaving the fibers, so that the fibers are the same in the vertical and horizontal directions. It is possible to configure a fiber sheet having the following optical properties.

Further, by changing the weaving ratio and the diameter of the fiber in the vertical direction and the horizontal direction, it is possible to make the optical properties in the vertical direction and the horizontal direction different as desired.

The present invention is not limited to the above-described embodiment, and it is needless to say that various modifications and applications are possible without departing from the gist of the invention.

[0133]

As described above, according to the fiber screen manufacturing method of the present invention according to the first aspect, a high-quality fiber sheet in which fibers are arranged at a pitch substantially equal to the diameter thereof can be obtained easily and with good productivity. Can be manufactured. In addition, since the adjacent fibers are bonded only at both ends, productivity can be further improved as compared with the case where the fibers are bonded over all side surfaces.

Further, according to the fiber screen manufacturing method of the present invention, the same effects as those of the first aspect are obtained, and the winding member is rotated by the rotary driving source. The drive force from the rotary drive source is reduced by a speed reducer so as to synchronize with the winding member rotated by the rotation of the guide frame by the drive force transmitted from the speed reducer and synchronized with the rotation of the winding member. Driving, receiving the driving force while being guided by the guide frame, so as to send out the fiber while moving the fiber guide so that winding around the winding member is performed at a pitch substantially equal to the diameter of the fiber, The pitch for aligning the fibers can be accurately maintained, and a higher quality fiber screen can be manufactured.

Furthermore, according to the fiber screen manufacturing method of the present invention, the same effect as that of the invention described in claim 2 can be obtained, and the circumference of the drum as a winding member having a cylindrical or cylindrical shape can be obtained. A groove is formed on the surface so as to be parallel to the central axis of the cylinder or the center of the cylinder, and the steps of bonding and cutting are performed along this groove, so that these steps can be performed accurately and easily. In addition, the peripheral surface of the drum is not damaged in the cutting step.

According to the fiber screen manufacturing method of the present invention, a winding member having a plurality of rod-shaped members arranged so as to be substantially parallel to each other at a predetermined distance is used. Thus, the same effect as the invention according to claim 2 can be obtained.

According to the fiber screen manufacturing method according to the fifth aspect of the present invention, the same effects as those of the second aspect can be obtained, and the fiber sheet can be set at a temperature lower by 50 ° C. than the glass transition temperature. As described above, since the flattening is performed by heating at a temperature equal to or lower than (temperature lower than the glass transition point temperature by 10 ° C.), the flattening can be surely performed even if there is a curl.

According to the fiber screen manufacturing method of the present invention, a plurality of fibers are arranged in a planar state, so that the surface shape is periodically repeated at a predetermined pitch. In order to closely transfer the film along the surface shape to the fiber sheet presenting the pattern, without impairing the unevenness of the surface, increase the thickness of the fiber screen to reinforce and also assist optical performance etc. It is possible to do.

According to the fiber screen manufacturing method of the present invention, the same effect as that of the invention described in claim 6 can be obtained, and the fiber sheet and the film are fixed on the stage, and the stage is placed in the housing. Housed,
Air is sucked by a vacuum pump from this housing to bring the vicinity of the fiber sheet and film closer to vacuum, and the inside of the housing is heated by a heater, so that no air layer is mixed between the fiber sheet and the film. The transfer can be reliably performed in close contact.

According to the fiber screen manufacturing method of the present invention according to the eighth aspect, the same effect as that of the sixth aspect of the present invention can be obtained, and at the same time, the film is formed by an object which can be brought into contact with an object with hydrostatic pressure. , The film can be closely transferred without damaging the irregularities on the fiber sheet surface.

According to the fiber screen manufacturing method of the ninth aspect of the present invention, the object which can be brought into contact with the hydrostatic pressure is a low-hardness elastic member or a gas or liquid sealed by an elastic seal member. By using the same, the same effect as the invention described in claim 8 can be obtained.

According to the fiber screen manufacturing method of the present invention, a pressing member having a pressing surface having a shape corresponding to a concave and convex pattern periodically repeated at a predetermined pitch of the fiber sheet is formed on the film. By pressing against the fiber sheet to transfer the film in close contact, the same effect as the invention according to claim 6 can be obtained.

According to the fiber screen manufacturing method of the present invention according to the eleventh aspect, the same effects as those of the tenth aspect are exhibited, and the fiber sheet is formed on the peripheral surface of the columnar or cylindrical member. By using a pressing member having a shape corresponding to a concavo-convex pattern that is periodically repeated at a predetermined pitch, the film can be easily transferred to the fiber sheet simply by rotating the pressing member.

According to the fiber screen of the present invention, the film constituting the fiber screen is made of polyvinyl chloride, polyethylene, polyimide, ethylene vinyl alcohol, an acrylic or epoxy or polyimide resist material, Alternatively, by forming the fiber screen using any one of the silicon-based resins, the fiber screen can be easily manufactured using the fiber screen manufacturing method according to the sixth aspect.

According to the fiber screen of the present invention, the film constituting the fiber screen has a film base and an adhesive layer formed on the surface of the film base on the side in contact with the fiber sheet. When the fiber screen is manufactured using the fiber screen manufacturing method according to the sixth aspect, the adhesive layer allows the film to be securely bonded to the fiber sheet.

According to the fiber screen of the present invention, the same effects as those of the invention described in claim 13 can be obtained, and the film base is softened by forming the adhesive layer with a hot melt adhesive. Since the heating step can also serve as the step of melting the adhesive, it can be manufactured more easily.

According to the fiber screen of the present invention, fibers which are not directly bonded except for both end portions are indirectly fixed by closely transferring the film to the fiber sheet surface. A fiber sheet manufactured using the fiber screen manufacturing method according to claim 1 is used while eliminating the need for bonding over all side surfaces of the fibers, thereby simplifying the manufacturing process and improving productivity. Thus, the fiber screen can be manufactured by using the fiber screen manufacturing method according to the sixth aspect.

According to the fiber screen of the present invention, when a fiber screen is manufactured by using the fiber screen manufacturing method of the sixth aspect, a film obtained by laminating a plurality of film bases is used. Thereby, the strength of the fiber screen increases,
Optical performance can be changed as desired.

According to the fiber screen of the present invention, desired optical performance can be obtained in a plurality of different directions by weaving the first fiber group and the second fiber group. Becomes

According to the fiber screen of the eighteenth aspect of the present invention, the same effect as that of the invention of the seventeenth aspect is obtained, and the fibers constituting the first fiber group and the second fiber group are constituted. By making the diameters of these fibers different from each other, it becomes possible to make the optical performance different between the arrangement direction of the first fiber group and the arrangement direction of the second fiber group.

According to the nineteenth aspect of the present invention, the same effect as that of the seventeenth aspect can be obtained, and the weaving ratio between the first fiber group and the second fiber group is 1: 1. By doing so, it is possible to make the optical performance the same in the arrangement direction of the first fiber group and the arrangement direction of the second fiber group.

According to the fiber screen of the present invention, the same effect as that of the invention according to the seventeenth aspect can be obtained, and the weaving ratio between the first fiber group and the second fiber group is m: n (m and n are mutually prime 1
With the above integer and excluding the case where m = n = 1), the optical performance can be made different between the arrangement direction of the first fiber group and the arrangement direction of the second fiber group. .

[Brief description of the drawings]

FIG. 1 is a front view and a side view showing one configuration example of a fiber winding device for winding a fiber around a winding member in a first embodiment of the present invention.

FIG. 2 is a front view and a side view showing another configuration example of a fiber winding device for winding a fiber around a winding member in the first embodiment.

FIG. 3 is a diagram showing a process of creating a fiber sheet by expanding the fiber wound on a drum in the first embodiment.

FIG. 4 is a diagram showing the entire configuration of the first embodiment in which a film is closely transferred to a fiber sheet using compressed gas or liquid.

FIG. 5 is a sectional view showing the internal configuration of the film transfer device in FIG. 4;

FIG. 6 is a sectional view showing another example of the internal configuration of the film transfer device according to the first embodiment.

FIG. 7 is a cross-sectional view showing a state in which a film is closely transferred to a fiber sheet by a pressing plate having a corrugated portion in the first embodiment.

FIG. 8 is a cross-sectional view showing still another example of the internal configuration of the film transfer device in the first embodiment.

FIG. 9 is a perspective view and a cross-sectional view illustrating a configuration example of a film that is closely transferred to a fiber sheet in the first embodiment.

FIG. 10 is a diagram showing a state in which a light beam is diffused when it is incident on a fiber screen formed by closely transferring a film to a fiber sheet in the first embodiment.

FIG. 11 is a perspective view and a side view showing a fiber sheet in which fibers are alternately woven vertically and horizontally one by one in the second embodiment of the present invention.

FIG. 12 is a perspective view showing a fiber sheet formed by alternately weaving two fibers vertically and horizontally in the second embodiment.

FIG. 13 is a perspective view showing a fiber sheet in which fibers are alternately woven in one direction in one direction and two directions in another direction in the second embodiment.

FIG. 14 is a view showing a state of light diffusion when the fiber sheet of FIG. 11 is approximately modeled.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Fiber screen 1a ... Convex part 1b ... Concave part 3, 3A, 3B, 3C, 3A '... Fiber sheet 4 ... Film 4a ... Film base 4b ... Adhesive layer 10, 10a, 10b ... Adhesive part 11 ... Drum (winding member) 11b ... groove 12 ... motor (rotary drive source) 13, 15 ... belt 14 ... reducer 16 ... guide frame 17 ... fiber guide 18 ... fiber 18A ... vertical fiber group 18B ... horizontal fiber group 19 ... winding member 19a ... rod bar (Rod-shaped members) 21, 21A, 21B: Film transfer device 22: Supply device 23: Vacuum pump 31, 31B: Housing 31a: First chamber 31b: Second chamber 31c: Third chamber 32 ... Partition wall 33: Film member ( Sealing member) 34 Heater 35 Stage 36a, 36b Press plate 36c Corrugated portion (press type) 37 Roller 38 … Spindle 39… Guide

Claims (20)

[Claims] 1. A step of winding a single fiber around a winding member while aligning the fiber at a pitch substantially equal to the diameter of the fiber, and winding the fiber wound around the winding member in a direction substantially perpendicular to the winding direction. A step of forming a fiber sheet by cutting substantially the center of the linearly bonded portion of the fiber wound around the winding member, the step of bonding the fiber sheet in a linear manner, A fiber screen manufacturing method, comprising manufacturing a fiber screen provided with: 2. A step of rotating the winding member by a rotary drive source; and reducing a driving force from the rotary drive source by a speed reducer so as to synchronize with the winding member rotated by the rotary drive source. A step of driving the guide frame by a driving force transmitted from the speed reducer and synchronized with the rotation of the winding member; and receiving the driving force while being guided by the guide frame, The fiber screen manufacturing method according to claim 1, further comprising: sending out the fiber while moving the fiber guide so that the winding is performed on the winding member at a pitch substantially equal to the diameter. 3. The drum according to claim 1, wherein the winding member is a drum having a cylindrical shape or a cylindrical shape, and a groove formed on a peripheral surface thereof so as to be parallel to the cylindrical central axis or the cylindrical central axis. The method according to claim 2, wherein the step of cutting and cutting is performed along the groove. 4. The winding member according to claim 2, wherein the winding member has a plurality of rod-shaped members arranged so as to be substantially parallel to each other at a predetermined distance. Fiber screen manufacturing method. 5. A step of heating and flattening the fiber sheet at a temperature not lower than (temperature lower than the glass transition point temperature by 50 ° C.) and not higher than (temperature lower than the glass transition point temperature by 10 ° C.). The method according to claim 2, further comprising: 6. A fiber sheet having an uneven pattern whose surface shape is periodically repeated at a predetermined pitch by arranging a plurality of fibers in a state of being arranged in a plane. A step of closely transferring a film along the fiber screen. 7. A step of fixing a fiber sheet and a film on a stage; a step of housing the stage in a housing; and drawing air from the housing by a vacuum pump to evacuate the vicinity of the fiber sheet and the film. The method for producing a fiber screen according to claim 6, further comprising: a step of approaching; and a step of heating the inside of the housing with a heater. 8. The step of closely transferring the film is performed by an object capable of contacting with an object with hydrostatic pressure.
The method according to claim 6, wherein the method is performed by pressing the film against the fiber. 9. The object which can be brought into contact with the hydrostatic pressure,
The method according to claim 8, wherein the fiber screen is a gas or a liquid sealed by a low-hardness elastic member or an elastic seal member. 10. The step of closely transferring the film comprises: pressing a pressing member having a pressing surface having a shape corresponding to an uneven pattern periodically repeated at a predetermined pitch of the fiber sheet from above the film. The method for producing a fiber screen according to claim 6, wherein the method is performed by pressing against a fiber sheet. 11. The pressing member is a member having a cylindrical shape or a cylindrical shape, and a shape corresponding to an uneven pattern that is periodically repeated at a predetermined pitch of the fiber sheet is formed on a peripheral surface thereof. The method for manufacturing a fiber screen according to claim 10, wherein 12. A fiber screen manufactured by using the fiber screen manufacturing method according to claim 6, wherein a film constituting the fiber screen is made of polyvinyl chloride, polyethylene, polyimide, ethylene vinyl alcohol, A fiber screen formed of any one of an acrylic, epoxy, or polyimide resist material and a silicon resin. 13. A fiber screen manufactured by using the fiber screen manufacturing method according to claim 6, wherein a film constituting the fiber screen includes a film base and a film base on a side in contact with the fiber sheet. And a bonding layer formed on a surface of the fiber screen. 14. The adhesive layer according to claim 13, wherein the adhesive layer is made of a hot melt adhesive.
The fiber screen according to item 1. 15. A fiber screen manufactured using the fiber screen manufacturing method according to claim 6, using the fiber sheet manufactured using the fiber screen manufacturing method according to claim 1. A fiber screen wherein fibers which are not directly bonded except for both end portions are indirectly fixed to each other by closely transferring the film to a fiber sheet surface. 16. A fiber screen manufactured by using the fiber screen manufacturing method according to claim 6, wherein a film constituting the fiber screen is formed by laminating a plurality of film bases. Characterized fiber screen. 17. A first fiber group in which a plurality of fibers having a substantially circular cross section are arranged in one direction, and a plurality of fibers having a substantially circular cross section are alternately arranged in another direction intersecting the one direction. And a second fiber group arranged in a weaving manner. 18. The fiber screen according to claim 17, wherein the fibers constituting the first fiber group and the fibers constituting the second fiber group have different diameters. . 19. The fiber screen according to claim 17, wherein the weaving ratio between the first fiber group and the second fiber group is 1: 1. 20. The weaving ratio between the first fiber group and the second fiber group is m: n (m and n are mutually prime integers of 1 or more and m = n = 1) 18. The fiber screen according to claim 17, wherein the fiber screen is excluded.