JP2006221018A - Method and apparatus for manufacturing optical sheet, and optical sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an optical sheet of satisfactory quality, in which a streak pattern is hindered from occurring and the quality of its appearance is improved. <P>SOLUTION: A ultraviolet curing type photosensitive layer 21 is formed on the flat side of a lenticular lens sheet 151, a ultraviolet ray is emitted to the photosensitive layer 21 from the lenticular lens side. A curable section and an uncurable sections are formed based on the condensation of the lenticular lens and thus a light shield pattern is formed. The formation of the light shield pattern involves placing a light shield layer transfer film onto the photosensitive layer 21, the light shield layer is transferred onto the uncurable section of the photosensitive layer, and then a transfer film is peeled. The peeling process uses a peeling blade 31 that has a curvature radius of 5 mm or less at its leading end, a kinetic friction coefficient of 0.2 or less, and contains polyolefine, polyethylene fluoride or one or more types of a copolymer of these. The peeling process alternatively uses a peeling roll 35 that has a diameter of 100 mm or smaller. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to an optical sheet manufacturing method, an optical sheet manufacturing apparatus and an optical sheet, in particular, an optical sheet manufacturing method such as a lenticular lens sheet used for a rear projection type screen such as a rear projection television, and an optical sheet. The present invention relates to a manufacturing apparatus and an optical sheet.

  Generally, a rear projection screen used for a rear projection television or the like has a configuration in which two or three lens sheets are overlapped. One Fresnel lens sheet of the lens sheet is disposed on the light source side, and has a function of narrowing the image light from the CRT light source or the image light transmitted through the liquid crystal so as to be within a certain angle range. The other lenticular lens sheet is disposed on the viewer side and has a function of expanding the image light transmitted through the Fresnel lens sheet to an appropriate angle range.

  In particular, a lens sheet having a fine pitch is required for a high-definition and high-quality rear projection type liquid crystal projection television. Such a lens sheet structure is disclosed in, for example, Patent Document 1. FIG. 12 shows the structure of the lens sheet disclosed in Patent Document 1. As shown in FIG. 12, the lens sheet 101 includes a lenticular lens sheet 102, an external light absorption layer 103, a diffusion layer 104, and a transparent resin sheet 105.

  As the lenticular lens sheet 102, for example, a form constituted by a lens portion made of an ultraviolet curable resin on a transparent support, or one formed by extrusion molding with a thermoplastic resin is used.

  On the exit surface side of the lenticular lens sheet 102, an external light absorbing layer 103 is provided at a non-condensing position of the lenticular lens 1021, that is, a light non-passing position. By providing the external light absorbing layer 103, the light reflected from the exit surface of the lenticular lens sheet 102 and returning to the viewer side among the external light incident on the lenticular lens sheet 102 is reduced, thereby improving the image contrast. It is done.

  The external light absorbing layer 103 is formed by forming a photosensitive layer on the flat portion of the lenticular lens sheet 102, and then affixing a transfer film coated with a black paint on the photosensitive layer, to the portion of the photosensitive layer where the diffusion layer 104 is formed. It is formed by transferring a black paint (see Patent Document 2).

  Further, a diffusion layer 104 is provided on the exit surface side of the lenticular lens sheet 102. In the lens sheet 101, the viewing angle performance in the horizontal direction is obtained mainly by diffusion by the incident lens, but the diffusion performance in the vertical direction is achieved by the diffusion layer 104.

 The lenticular lens sheet 2 is provided with a transparent resin sheet 105 called a front plate via a diffusion layer 104. The transparent sheet 105 protects the lenticular lens sheet 102. It is provided for the purpose of obtaining a surface gloss similar to that of a general CRT television. The observer side of the transparent sheet 105 is provided with a functional film such as an antireflection film or a hard coat film for the purpose of improving external light contrast by suppressing reflection of external light or improving durability. It is often done. These functional films are often formed by a transfer method.

In addition, although not shown in FIG. 12, a Fresnel lens sheet is generally provided on the incident surface side of the lenticular lens sheet 102. This Fresnel lens sheet is composed of a sheet in which a Fresnel lens composed of concentric and fine pitch lenses at equal intervals is provided on the light exit surface.
JP 09-120101 A JP 2001-113538 A

  When a functional film or the like is transferred to the optical sheet, the sheet vibrates in the process of attaching and peeling the transfer film, and the transferred functional film generates a stripe pattern in the width direction, impairing the appearance quality. There was a problem. Hereinafter, the vibration or the streak pattern caused by the vibration may be described as zipping.

Further, after forming a photosensitive layer on the flat part of the lenticular lens sheet 102, a sheet is vibrated in the process of applying and peeling a transfer film coated with a black paint on the photosensitive layer, and the width direction stripes are applied to the transferred black paint. There was a problem that the appearance of the pattern was impaired and the appearance quality was impaired. This streak pattern may be reduced depending on conditions such as the tension of the sheet or transfer film, the peeling angle, and the peeling speed, but it is difficult to reduce it stably. Met.

  In addition, when peeling is performed continuously for a long time, the surface of the base film is rubbed due to friction with the peeling blade, and powdery foreign matter accumulates on the tip of the peeling blade, causing a streak pattern in the flow direction, In some cases, a streak pattern is generated in the width direction by entraining the foreign matter.

  The present invention was made in order to solve such problems, and a method for producing an optical sheet capable of inexpensively forming a high-quality optical sheet that improves the appearance quality by suppressing the generation of streaks. And a manufacturing apparatus, and an optical sheet manufactured thereby.

  The present invention according to claim 1, which achieves the above object, is a method for producing an optical sheet such as a lenticular lens sheet or a prism lens sheet used in a rear projection type screen, wherein the method for producing an optical sheet comprises a lens portion. Forming an optical sheet main body, a step of forming a photosensitive layer on a flat surface opposite to the lens portion of the optical sheet main body, and an ultraviolet ray or the like from the lens portion side of the optical sheet main body to the photosensitive layer. Irradiating light, and forming a light-shielding pattern having a cured portion and an uncured portion based on the light collected by the lens portion, and the step of forming the light-shielding pattern comprises the step of: After placing the light shielding layer on the photosensitive layer and transferring the light-shielding layer to the uncured portion of the photosensitive layer, a peeling blade having a diameter of 100 mm or less equipped with a peeling blade or a driving mechanism is provided. By a roll, to provide a method of manufacturing an optical sheet forming the light-shielding pattern is peeled off the transfer film.

  According to this configuration, in the step of forming the light shielding pattern, a transfer film having a light shielding layer is disposed on the photosensitive layer of the optical sheet body, and after the light shielding layer is transferred to an uncured portion of the photosensitive layer, The transfer film is peeled off by a peeling blade or a peeling roll. In this case, the optical sheet body is prevented from vibrating.

 In particular, if the radius of curvature of the tip of the peeling blade is 5 mm or less, the optical sheet main body is more reliably prevented from vibrating during film peeling. Moreover, even if the diameter of the peeling roll is set to 100 mm or less, the optical sheet main body is similarly more reliably prevented from vibrating.

  The present invention according to claim 2 is an apparatus used when manufacturing an optical sheet such as a lenticular lens sheet or a prism lens sheet, and after transferring a functional film by attaching a transfer film to the optical sheet body. There is provided a device for producing an optical sheet having means for peeling the transfer film, the peeling means including a peeling blade, and a radius of curvature of a tip portion of the peeling blade being 5 mm or less.

  According to this configuration, the transfer film is peeled off by the peeling blade having a curvature radius of 5 mm or less at the tip portion, so that the optical sheet main body is prevented from vibrating during peeling.

  According to a third aspect of the present invention, there is provided the optical sheet manufacturing apparatus according to the second aspect, wherein the dynamic friction coefficient of the material of the tip surface of the peeling blade is 0.2 or less.

  According to this configuration, since the dynamic friction coefficient at the tip of the peeling blade is 0.2 or less, the dynamic friction force generated between the transfer film and the peeling blade is reduced when the transfer film is peeled off.

  The invention according to claim 4 is the optical sheet according to claim 2 or 3, wherein the material of at least the surface of the tip portion of the peeling blade contains at least one of polyolefin, polyfluorinated ethylene, or a copolymer thereof. A manufacturing apparatus is provided.

  According to this structure, since the surface of the tip part of the peeling blade is made of a material containing one or more of polyolefin, polyfluorinated ethylene, or a copolymer thereof, dynamic friction is caused on the surface of the metal body part of the peeling blade. A functional part having a coefficient of 0.2 or less and a smooth surface is formed.

  Invention of Claim 5 is an apparatus used when manufacturing optical sheets, such as a lenticular lens sheet | seat and a prism lens sheet | seat, Comprising: After attaching a transfer film to the said optical sheet main body, and transferring a functional film, It has a means for peeling a transfer film, and the peeling means includes a peeling roll, and the diameter of the peeling roll is 100 mm or less.

  According to this structure, since the diameter of a peeling roll is 100 mm or less, when peeling a transfer film, the dynamic friction force produced between a transfer film and a peeling roll becomes small.

 According to a sixth aspect of the present invention, there is provided the optical sheet manufacturing apparatus according to the fifth aspect, wherein the peeling roll includes a drive mechanism.

  According to this configuration, since the peeling roll includes the drive mechanism, when the transfer film is peeled, the effective tension can be prevented from being lowered by the action of the tension of the transfer film rotating the peeling roll.

  According to a seventh aspect of the present invention, the optical sheet comprises a lenticular lens sheet used for a rear projection type screen, and means for forming a lenticular lens sheet main body having a lens portion; and a lens portion of the lenticular lens sheet main body; A means for forming a photosensitive layer on the opposite flat surface, and the photosensitive layer is irradiated with light from the lens portion side of the lenticular lens sheet main body, and the cured portion and the unexposed portion are collected based on the light collected by the lens portion. Means for forming a light-shielding pattern having a cured portion, wherein the light-shielding pattern forming means has a transfer film having a light-shielding layer disposed on the photosensitive layer, and the light-shielding layer is formed on an uncured portion of the photosensitive layer. The apparatus for producing an optical sheet according to claim 2, wherein the transfer film is peeled off to form a light-shielding pattern after transferring the film. To provide.

  According to this configuration, a transfer film having a light shielding layer is disposed on the photosensitive layer of the lenticular lens sheet main body, and after transferring the light shielding layer to an uncured portion of the photosensitive layer, the transfer film is removed by a peeling blade or a peeling roll. To peel off. In this case, by using a peeling blade having a radius of curvature of 5 mm or less or a peeling roll having a diameter of 100 mm or less, the lenticular lens sheet main body is well prevented from vibrating during film peeling.

  The invention according to claim 8 provides the apparatus for producing an optical sheet according to claim 7, wherein the light is an ultraviolet ray, and the photosensitive layer is an ultraviolet curable photosensitive resin.

  According to this configuration, the photosensitive layer is formed by irradiating an ultraviolet curable photosensitive resin with ultraviolet rays.

  The invention according to claim 9 provides the optical sheet manufactured by using the optical sheet manufacturing apparatus according to any one of claims 2 to 8, wherein the optical sheet is a lenticular lens sheet.

  According to this configuration, the lenticular lens sheet body is manufactured without vibration when the transfer film is peeled off.

  In the invention according to claim 1, since the vibration of the optical sheet main body is prevented when the transfer film is peeled off, it effectively suppresses the generation of a stripe pattern in the width direction in the transferred photosensitive layer, It is possible to provide a method of manufacturing an optical sheet that can improve the appearance quality of the optical sheet.

  Since the optical sheet main body is prevented from vibrating when the transfer film is peeled off, it is possible to prevent generation of a stripe pattern in the width direction on the functional film, and high surface unevenness pattern accuracy. An apparatus for producing a uniform optical sheet to which is transferred can be obtained at low cost.

  In the invention described in claim 3, since the dynamic friction force generated between the transfer film and the peeling blade is reduced, in addition to the effect of the invention described in claim 2, it is further effective that the stripe pattern in the width direction is generated in the photosensitive layer. Can be prevented.

  In the invention according to claim 4, since the tip surface of the metal main body portion of the peeling blade is formed of a material containing at least one of polyolefin, polyfluorinated ethylene, or a copolymer thereof, claim 2 is provided. Alternatively, in addition to the effect of the invention described in 3, a functional surface having a small dynamic friction coefficient and a smooth surface can be easily formed at the tip of the peeling blade.

  According to the fifth aspect of the present invention, since the dynamic frictional force between the transfer film and the peeling roll becomes smaller, it is possible to effectively prevent the stripe pattern in the width direction from being generated in the photosensitive layer.

 Since the invention according to claim 6 can prevent the effective tension from being lowered due to the action of the transfer film rotating the peeling roll, in addition to the effect of the invention according to claim 5, The peeling roll of the present invention functions effectively, and it is possible to prevent the streak pattern from being generated in the photosensitive layer more reliably.

  Since the invention according to claim 7 can prevent the lenticular lens sheet body from vibrating when the transfer film is peeled off, in addition to the effect of the invention according to claim 2, 3, 4, 5 or 6, It is possible to prevent a stripe pattern in the width direction from being generated on the film (photosensitive layer) and to provide a high-quality lenticular lens sheet free from appearance defects such as missing touches at a low cost.

  The invention according to claim 8 has the merit that the photosensitive layer can be easily formed in addition to the effect of the invention according to claim 7 because the photosensitive layer can be formed only by irradiating the ultraviolet curable photosensitive resin with ultraviolet rays. .

  Since the invention according to claim 9 can suppress vibration of the lenticular lens sheet main body at the time of peeling of the transfer film, in addition to the invention according to any one of claims 2 to 8, a photosensitive layer which is a functional film is provided. It is possible to easily mass-produce a lenticular lens sheet excellent in appearance quality by preventing the occurrence of a streak pattern.

  The best embodiment according to the present invention is to manufacture an optical sheet such as a lenticular lens sheet used for a rear projection type screen by forming an optical sheet main body having a lens portion, and a flat surface opposite to the lens portion of the optical sheet main body. A photosensitive layer is formed on the surface, and the photosensitive layer is irradiated with light such as ultraviolet rays from the lens portion side of the optical sheet main body, and a cured portion and an uncured portion are formed based on light collection by the lens portion. When the light shielding pattern is formed, a transfer film having a light shielding layer is disposed on the photosensitive layer, and after the light shielding layer is transferred to an uncured portion of the photosensitive layer, the transfer film The light-shielding pattern is formed by peeling the film, and in particular, the means for peeling the transfer film is a peeling blade having a radius of curvature of the tip portion of 5 mm or less or a roll diameter of 100 mm or less. By including a release roll, high-quality optical sheet is improved appearance quality by suppressing the occurrence of streaks can be formed inexpensively.

  The peeling blade desirably has a dynamic friction coefficient of 0.2 or less of the material of the tip surface thereof, and more preferably a peeling blade having a drive mechanism. In this case, it is more desirable that the material of the surface of the tip portion of the peeling blade contains at least one of polyolefin, polyfluorinated ethylene, or a copolymer thereof.

  Hereinafter, embodiments of the present invention will be described with reference to FIGS. Although the form of the manufacturing method of the lenticular lens sheet used for this invention is not specifically limited, The manufacturing method by extrusion molding is preferable. When manufactured using an ultraviolet curable resin, (1) the ultraviolet curable resin is expensive, resulting in higher production costs. (2) environmental stability due to the different materials of the lens part and the transparent support. (3) When the lens part and the transparent support are made of different materials, both materials are used. Due to the difference in refractive index, color unevenness occurs and transparency is limited. (4) Because the lens part and transparent support are made of different materials, crushing of the blade is likely to occur and the shapeability is also limited. This is because there is a problem that there is.

  First, the overall configuration of the lens sheet manufacturing method according to the embodiment of the present invention will be described with reference to FIG. FIG. 1 is a schematic diagram illustrating a configuration example of the entire lens sheet manufacturing apparatus. In FIG. 1, a lenticular lens sheet manufacturing apparatus is indicated by reference numeral 10, 11 is a die, 110 is an extruder, 12 is a first roll, 13 is a second roll, 14 is a third roll, 140 is a fourth roll, Reference numerals 141 and 142 denote transport rolls. As will be described later, an elastic roll is used as the first roll 12.

  In the lenticular lens sheet manufacturing apparatus 10, the following extrusion molding process is mainly performed. Specifically, first, the die 11 discharges the resin 15 melted by the extruder 110 and sends it to the air gap between the first roll 12 and the second roll 13. The discharged resin 15 is pressed against the second roll 13 by the first roll 12.

 At this time, the second roll 13 transfers the optical pattern of the lenticular lens to the resin 15 and cools the resin 15 with it. The lenticular lens sheet 151 on which the optical pattern is formed passes through the third roll 14 and the fourth roll 140 that function as annealing rolls, and is then conveyed by a pair of upper and lower conveyance rolls 141 and 142, and the extrusion molding process is completed.

  After such an extrusion molding process, a light shielding pattern printing process is performed. In FIG. 1, 201 and 202 are a pair of application rolls for applying an ultraviolet reactive resin, 210 is a drying device, 220 is an ultraviolet irradiation device, 230 is a roll, and 231 and 232 are a pair of ultraviolet inks. An application roll, 233 is a winding roll, 240 is an ultraviolet irradiation device, 250 is an ultraviolet irradiation device, and 260 is a roll of a winder.

  In the light shielding pattern printing step, first, an ultraviolet reactive (curable photosensitive) resin is applied to the emission-side flat surface of the lenticular lens sheet (optical sheet main body) 151 by the application rolls 201 and 202. The applied ultraviolet reactive resin is dried in the drying device 210 and then irradiated with ultraviolet rays in the ultraviolet irradiation device 220. The ultraviolet responsive resin is selectively cured by the lens function of the lenticular lens sheet 151.

 Thereafter, a film 160 formed by applying an ultraviolet photosensitive ink is pasted onto the ultraviolet reactive resin of the lenticular lens sheet 151. The film 160 is formed by applying ultraviolet photosensitive ink to the surface of the film sent from the roll 230 with the application rolls 231 and 232.

  The lenticular lens sheet 151 is irradiated with ultraviolet rays from the sheet flat surface side in the ultraviolet irradiation device 240 in a state where the film 160 is bonded. As a result, the ultraviolet photosensitive ink (functional film) is transferred from the film 160 to the uncured portion of the UV reactive resin having adhesiveness.

 After this transfer, the film 160 is peeled off from the ultraviolet reactive resin of the lenticular lens sheet 151, and the peeled film 160 is taken up by a roll 233. The lenticular lens sheet 151 from which the film 160 has been peeled is irradiated with ultraviolet rays by the ultraviolet irradiation device 250, and the ultraviolet reactive resin is completely cured. And the lenticular lens sheet 151 is wound up by the roll 260 of a winder, and a light shielding pattern printing process is complete | finished.

  Here, in order to peel the film 160, for example, a peeling blade 31 as shown in FIG. 8 is used. As a result of various studies on the shape and material of the peeling blade 31, the present inventors effectively suppress the vibration generated during peeling when the radius of curvature R of the tip shape portion of the peeling blade 31 is 5 mm or less. Then, it was found that the generation of the streaks can be suppressed.

 Furthermore, it is preferable that the dynamic friction coefficient of the material of the tip surface of the peeling blade 31 is 0.2 or less. The dynamic friction coefficient in the present invention is based on the evaluation of ASTM-D1894 (0.69 MPa, 3 m / min).

  Furthermore, the material of at least the tip surface of the peeling blade 31 contains at least one of (1) polyolefin, (2) polyfluorinated ethylene, (3) a polyolefin copolymer or a polyfluorinated ethylene copolymer. In this case, the effect of suppressing vibration and the generation of streaks due to the vibration is high, and the effect is most remarkable when the material is high-density polyethylene or polytetrafluoroethylene.

 In addition, when a problem arises in durability due to wear of these polyethylene and polyfluorinated ethylene, it is preferable to use a composite material with glass fiber, graphite or the like.

  FIG. 8 shows a state in which the peeling blade 31 is brought into contact with the roll. However, the peeling blade 31 of the present invention is not limited to this form of use, and for example, the film 160 and the peeling blade 31 are mutually connected on a conveyor. Alternatively, the peeling blade 31 may be brought into contact with the film 160 to which an appropriate magnitude of tension is applied.

  Furthermore, the same effect as described above was obtained when peeling was performed with the peeling roll 35 as shown in FIG. The diameter of the peeling roll 35 is required to be 100 mm or less, preferably 40 mm or less, and more preferably 30 mm or less. More preferably, the peeling roll 35 has a drive mechanism. Furthermore, when the dynamic friction coefficient of the material of the tip surface of the peeling blade 31 is 0.2 or less, and when peeling is performed by the peeling roll 35, it is possible to suppress the generation of powdery foreign matters due to wear of the base film 160. Particularly preferred.

  Here, the reason for the above effect will be considered. FIG. 8 shows a state in which an adhesive material is laminated on the upper plane portion of the lenticular lens sheet 151 and ink and a base film 160 are bonded to the upper surface of the lenticular lens sheet 151 and supplied to the roll 34. Then, the base film 160 is peeled upward at the upper part of the roll 34 via the peeling blade 31. The lenticular lens sheet 151 moves along the roll 34 in the lower right direction.

  FIG. 9 is an enlarged model of the vicinity of the tip of the peeling blade 31 in FIG. Since it is considered that tension is applied to the lenticular lens sheet 151 side and the lenticular lens sheet 151 side is not pulled up by the zipping and lifted from the roll 34, the roll 34 in FIG. Don't lose generality.

  Further, the base film 160 is lifted substantially vertically upward. For simplicity, it is assumed that the horizontal lenticular lens sheet 151 is lifted with a tension T in a substantially vertical direction as shown in FIG. Further, the movement of the lenticular lens sheet 151 and the base film 160 is the same as the peripheral speed V of the roll 34, and the plane in FIG.

  The substrate used for the transfer film is flexible enough to bend along the tip of the peeling blade 31 and FIG. 9 is illustrated as such. If there is no friction between the peeling blade 31 and the base film 160, when the base film 160 is pulled with a tension T, any portion along the radius of curvature R may be any of the arcs up to the fixed part at the lowest point. It can be assumed that tension T is applied.

 Therefore, as shown in FIG. 9, the base film 160 along the arc of the radius R with the tension T generates an adhesion force N in the center direction of the arc. In FIG. 9, if the adhesion force N is sufficiently large, the release point 36 is stabilized in the vicinity of the bottom, but it is considered that zipping occurs under the condition that the release force F and the adhesion force N antagonize. FIG. 10 shows this state.

  When the adhesion force N is smaller than the release force F, the peeling point 36 moves to the right from the state of FIG. At the same time, the base film 160 floats away from the roll. However, the lenticular lens sheet 151 side is kept in close contact. When the peeling point 36 moves to the right by the dimension p and becomes the state of FIG. 10 (b), the base film 160 has a longer circumferential length than the initial length and the tension becomes higher. Increased in addition to N adhesion strength.

 Further, since the peeling angle is increased, the apparent peeling force F is reduced and the peeling is easily performed. It is considered that due to the synergistic effect of both, the separation proceeds beyond the speed V and returns to the state of FIG.

  A frictional force always acts between the actual peeling blade 31 and the base film 160, and the tension T gradually decreases due to the influence of friction from the right side to the lower end in FIG. . Therefore, the tension of the base film 160 at the lowest point related to zipping becomes smaller than T, the adhesion force N to the roll also becomes smaller, and zipping is more likely to occur. Here, zipping means that the state (a) and the state (b) in FIG. 10 are periodically moved to become a vibration state. The present invention has been achieved by optimizing the shape and material of the peeling blade 31, that is, the coefficient of friction, and finding conditions under which a vibration state does not occur and conditions under which the vibration state is stabilized by disturbance.

  That is, it is presumed that by reducing the curvature of the blade tip, the zipping pitch becomes so small that it cannot be visually recognized and becomes inconspicuous. Further, the use of a specific material at the tip of the peeling blade 31 or the peeling with the peeling roll 35 reduces the friction coefficient at the tip of the peeling blade 31. Therefore, it is presumed that by increasing the tension T of the film 160 at the peeling point, peeling can be performed smoothly and irregular zipping can be suppressed, and as a result, the zipping has become inconspicuous. Furthermore, the reason why the smaller diameter of the peeling roll 35 is preferable is also presumed to be due to these synergistic effects.

  The reason why it is preferable that the peeling roll 35 has a drive mechanism is considered that the tension of the base film 160 prevents the effective tension from being lowered by the action of rotating the peeling roll 35. In addition, from the above consideration, it is clear that the peeling roll 35 needs high rotational accuracy, and it is necessary to appropriately select variations in roll diameter, surface accuracy, and bearing device. The explanation of the reason why the peeling blade 31 and the peeling roll 35 of the present invention function effectively in the countermeasure against zipping is completed.

  Next, the manufacturing method of the lens sheet in this invention is described. A method of manufacturing a lenticular lens sheet (optical sheet main body) having a lens surface (extrusion molding process unit 10A in FIG. 1) and a method of manufacturing a light shielding pattern (in FIG. 1) for forming a light shielding pattern on the opposite lens surface of the lenticular lens sheet A manufacturing method having the light-shielding pattern printing process unit 10B) will be described in order.

  First, the manufacturing method of a lenticular lens sheet is demonstrated in detail using FIG. FIG. 2 is a cross-sectional view showing an apparatus for manufacturing a lenticular lens sheet. In addition, although the manufacturing method of a lenticular lens sheet is demonstrated below, this invention is not restricted to this, It is also possible to manufacture optical sheets, such as a prism lens sheet, by another manufacturing method.

  As shown in FIG. 2, the lenticular lens sheet manufacturing apparatus 10 includes a die 11, a first roll 12, a second roll 13, and a third roll 14. The die 11 is a discharge member that discharges the resin 15 melted by the extruder 110. The discharge temperature of the resin 15 from the die 11 is preferably higher than 230 ° C and not lower than 250 ° C and not higher than 290 ° C. If it is lower than 230 ° C., the melt viscosity of the resin 15 becomes too high, and the transferability by the shaping roll may be insufficient. On the other hand, when the temperature is higher than 290 ° C., thermal decomposition of the resin 15 is promoted, and problems such as discoloration and cloudiness may occur.

  The first roll 12 is a touch roll that presses the molten resin 15 against the second roll 13 side. This first roll 12 is an elastic roll whose diametrical deformation amount is 0.01% or more of the diameter when the linear pressure is 30 kg / cm. If the material is a metal, it is a general carbon steel, hardened steel, etc. Such structural steel materials can be used, and in the case of rubber, heat-resistant silicon rubber, fluorine rubber, or the like can be used.

 Further, the first roll 12 may have a surface with low thermal conductivity. Thereby, it can prevent that the resin temperature of the resin 15 falls at the time of roll touch, and can maintain the resin temperature of the resin 15 high. When a metal elastic roll exhibiting elastic behavior is used as the first roll 12, an optical sheet having a concavo-convex shape on both sides is formed by forming an arbitrary shaping pattern also on the first roll 12 side. Is possible.

  The second roll 13 is a main cooling roll that cools and solidifies the resin 15 melted and discharged from the die 11. The second roll 13 is a general metal roll, but is a shaping roll whose surface is engraved with a mold of the lenticular lens 151. The mold pattern pitch of the mold formed on the second roll 13 is 290 μm or less, desirably 200 μm or less. The molding height from the reference surface of the mold is 0 μm or more and 100 μm or less, preferably 30 μm or less. The molding pattern is not limited to engraving, and can be formed using other conventional methods such as etching and blasting.

  In addition, the degree of freedom of the optical pattern to be transferred can be increased by winding a flat plate mold around the second roll 13 with an adhesive material. At the same time, the heat insulating property of the second roll 13 can be enhanced, and a functional optical sheet having a highly accurate thickness, transfer, and the like can be formed. Furthermore, the 3rd roll 14 is an annealing roll which makes the resin 15 cooled with the 2nd roll 13 into a sheet form, and sends it to a winding machine. The third roll 14 is a general metal roll like the second roll 13.

  Examples of the material of the resin 15 include a thermoplastic resin. For example, a polymethyl methacrylate resin, a polycarbonate resin, a polystyrene resin, a methyl methacrylate-styrene copolymer (hereinafter sometimes referred to as an MS resin), an AS resin, Examples thereof include ABS resin, polypropylene resin, polyethylene resin, polyethylene terephthalate resin, polyvinyl chloride resin, thermoplastic elastomer, and copolymers thereof.

 The resin 15 is particularly preferably a resin having a low melt viscosity such as a polycarbonate resin, an MS resin, an acrylic resin, or a PET resin. Furthermore, the resin 15 may contain an additive such as a light diffusing material or an antistatic material, or the lenticular lens sheet 151 may be either a single layer or multiple layers.

  As shown in FIG. 2, an air gap is provided between the die 11 and the nip positions of the rolls 12 and 13. The nip temperature of the resin 15 is determined by the size of the air gap and the discharge temperature of the resin 15 from the die 11. The size of the air gap is generally 120 mm or more, but in the present embodiment, it is preferably 110 mm or less. Thereby, at the time of a roll touch, the resin 15 can reach the rolls 12 and 13 faster to prevent the resin temperature of the resin 15 from decreasing, and the resin temperature of the resin 15 can be kept high.

  A roll gap through which the resin 15 passes is provided between the first roll 12 and the second roll 13. The size of the roll gap is set in accordance with the thickness of the lenticular lens sheet 151 formed from the resin 15, and can be set to 350 μm or less, for example, and preferably 200 μm or less.

  Next, a method for manufacturing the lenticular lens sheet 151 using the manufacturing apparatus 10 will be described in more detail. The molding speed of the lenticular lens sheet 151 is generally 4 to 5 m / min, but in the present embodiment, it is preferably 8 to 20 m / min, which is faster than this. Thereby, at the time of a roll touch, it can prevent that the resin temperature of the resin 15 falls, and can maintain the resin temperature of the resin 15 high.

  First, the melted resin 15 is discharged from the die 11, and the discharged resin 15 passes through the air gap from the nip position between the first roll 12 and the second roll 13 and between the rolls 12 and 13. It is sent to the provided roll gap. The resin 15 sent to the roll gap is pressed against the surface of the second roll 13 because the first roll 12 presses the second roll 13 with a predetermined pressing force. At this time, since the mold of the lenticular lens is provided on the second roll 13, the lenticular lens unevenness (lens portion unevenness shape) is formed on the resin 15.

  Here, the resin 15 is cooled by the second roll 13 that functions as a main cooling roll when passing through the roll gap of the rolls 12 and 13. Then, the resin 15 is taken out from the roll gap as a sheet on which irregularities of the lenticular lens are formed. Thereafter, the resin 15 is sent to a third roll 14 that functions as an annealing roll, becomes a lenticular sheet 151, and is sent to a winding device (not shown) for processing.

  Next, the aspect at the time of the roll press of the 1st roll 12 and the 2nd roll 13 is demonstrated in detail. First, the aspect in a cross section perpendicular | vertical with respect to the longitudinal direction of the rolls 12 and 13 is demonstrated using FIG. FIG. 3 is a schematic cross-sectional view showing the collapse of the first roll 12.

  Fig.3 (a) is a schematic sectional drawing which shows a cross section perpendicular | vertical to the longitudinal direction of the 1st roll 12 before roll press. At the time of roll pressing, the first roll 12 presses the second roll 13 in the left-right direction in FIG. 3B, and the resin 15 is roll-pressed by these rolls 12, 13. Then, as shown in FIG.3 (b), the load W is applied to the 1st roll 12 from right and left in a figure. Due to this load W, the first roll 12, which is an elastic roll, is crushed and deformed, and becomes longer by a dimension δz in the vertical direction in the figure in a cross section perpendicular to the longitudinal direction.

 At this time, the cross section perpendicular to the longitudinal direction of the first roll 12 is shortened by the displacement δu in the left-right direction in the figure and becomes narrower. As a result, the second roll 13 is not crushed in the cross section parallel to the longitudinal direction, whereas the first roll 12 is elastic and therefore crushed and elongated in the cross section perpendicular to the longitudinal direction. The contact time of 13 can be lengthened.

  Then, the aspect in the cross section parallel to the longitudinal direction of the rolls 12 and 13 is demonstrated using FIG. FIG. 4 is a schematic cross-sectional view showing the bending of the first roll 12.

  Fig.4 (a) is a schematic sectional drawing which shows a cross section parallel to the longitudinal direction of the 1st roll 12 before roll press. At the time of roll pressing, the first roll 12 presses the second roll 13 up and down in FIG. 4B, and both the rolls 12 and 13 roll press the resin 15. Then, as shown in FIG.4 (b), the load W is applied to the 1st roll 12 from the upper and lower sides in the figure. Due to this load W, the first roll 12, which is an elastic roll, bends in the vertical direction in the figure in a cross section parallel to the longitudinal direction. Thereby, since the 1st roll 12 has elasticity, it can bend in the cross section parallel to a longitudinal direction, and the contact length of both the rolls 12 and 13 can be lengthened.

  Thus, when using an elastic roll for the 1st roll 12, when the 1st roll 12 deforms in the direction perpendicular to the longitudinal direction, the contact time of the 2nd roll 13 in which the metallic mold was formed, and resin 15 In addition, the contact length can be increased. Moreover, when the 1st roll 12 which is an elastic roll is rubber | gum, the 1st roll 12 can be made to contact and be pressed by the 2nd roll 13 which is a metal mold | die roll (by pushing).

 On the other hand, when the surface of the first roll 12 is made of an elastic metal or the like and cannot be used by contacting the surface with the second roll 13 (by pressing), the central portion of the first roll 12 that is an elastic roll is inflated. The crowning roll. Thereby, when the 1st roll 12 and the 2nd roll 13 contact, those contact time and contact length can be lengthened.

  Next, a preferred embodiment in which an elastic roll is used as the first roll 12 in the above-described lenticular lens sheet manufacturing method will be described. For example, when the first roll 12 is a metal elastic roll, the first roll 12 is deformed by 1.8 mm (0.45% of the diameter) in the direction of the load W at a roll diameter of 400 mm and a linear pressure of 30 kg / cm. The contact length of the resin 15 (corresponding to the length L in FIG. 3) is 54.9 mm.

  On the other hand, when the first roll 12 is a general metal roll, this metal roll has a roll diameter of 400 mm, a wall thickness of 50 mm, and a linear pressure of 30 kg / cm. 0025%) Deformation. Due to this deformation, the contact length of the resin 15 becomes about 4.2 mm.

  For example, when the first roll 12 is a metal elastic roll, the first roll 12 is deformed by 280 μm (0.11% of the diameter) in the direction of the load W at a roll diameter of φ250 mm and a linear pressure of 30 kg / cm, The contact length of 15 is 16 mm.

  On the other hand, when the first roll 12 is a normal metal roll, this metal roll has a roll diameter of φ250 mm and a load of 1.7 μm (0.0007% of the diameter) in the direction of the load W at a linear pressure of 30 kg / cm. Due to the deformation, the contact length of the resin 15 becomes 1.26 mm.

  When the elasticity of the first roll 12 is less than 0.01% of the diameter as the amount of deformation in the diameter direction when the linear pressure is 30 kg / cm, the resin pressure increases at the roll nip position of the rolls 12 and 13, and the rolls 12 and 13 And the thickness accuracy in the width direction of the lenticular lens sheet 151 cannot be controlled.

 In this case, it becomes sensitive to disturbances such as the discharge behavior of the resin 15 and the cooling team, and it becomes difficult to stably maintain the thickness accuracy and appearance uniformity. In this case, a highly rigid roll and a special structure for pressing the roll at a high pressure are required separately to allow the resin 15 to sufficiently flow into the mold, and the manufacturing equipment is expensive accordingly.

  If the elasticity of the first roll 12 is larger than 10% of the diameter as the amount of deformation in the diameter direction when the linear pressure is 30 kg / cm, the deformation of the first roll 12 becomes larger by losing the resin pressure of the resin 15, and the thickness It becomes difficult to control the accuracy and shaping rate. Furthermore, in this case, it is difficult to produce the first roll 12 that stably realizes performance, and the durability of the first roll 12 is lowered.

  Under the above conditions, the lenticular lens sheet 151 manufactured by the manufacturing apparatus 10 has a thickness of 350 μm or less, desirably 200 μm or less, a molding pattern pitch of 290 μm or less, desirably 200 μm or less, and a molding height of 0 μm. The sheet is 100 μm or less, desirably 30 μm or less, and the transfer rate is 90% or more, desirably 95% or more. Further, the elasticity of the first roll 12 is preferably in the range of 0.05% to 1.0% of the diameter as a deformation amount in the diameter direction when the linear pressure is 30 kg / cm, and is 0.1% More preferably, it is in the range of -0.5%.

  As described above, the discharge temperature of the resin 15 from the die 11 is increased, the molding speed is increased, the resin 15 reaches the rolls 12 and 13 quickly, the air gap is further reduced, and the resin 15 resin at the time of roll touch is reduced. The temperature can be kept high. Thereby, the resin viscosity of the resin 15 can be reduced, and the resin pressure at the time of roll press can be reduced. Further, when a resin having a low melt viscosity is used as the resin 15, the resin viscosity can be further reduced, and the resin pressure during the roll can be further reduced.

  As described above, since the resin pressure of the resin 15 is low, it is possible to prevent the resin pressure from rapidly increasing during the roll press, and the rolls 12 and 13 are subjected to the reaction force to bend due to the sudden increase in the resin pressure. It can be avoided. Thereby, distribution of the part which both rolls 12 and 13 contact can be made uniform, and thickness distribution of resin 15 can be made uniform.

  Furthermore, since the resin viscosity of the resin 15 is low, it becomes possible to smoothly flow the resin 15 into the shaping pattern of the second roll 13 at the time of roll pressing, improving the transferability and molding accuracy of the molding die to the resin 15. can do.

  Next, the manufacturing method of the light shielding pattern will be described in detail with reference to FIG. Here, a method for producing a light-shielding pattern by the black ink layer transfer film 160 using the difference in adhesiveness of the polymer layer will be described. FIG. 5 is a process cross-sectional view illustrating a method for manufacturing a light shielding pattern.

  As shown in FIG. 5A, the photosensitive layer 21 is formed on the flat surface (surface opposite to the lens portion) of the lenticular lens sheet 151 formed as described above. The photosensitive layer 21 can be formed using, for example, an ultraviolet curable photosensitive resin. The photosensitive layer 21 is formed by direct printing, and is formed by applying a photosensitive resin to the flat surface of the lenticular lens sheet 151 using a gravure roll or the like. A protective layer 22 is formed on the photosensitive layer 21.

  As shown in FIG. 5B, the photosensitive layer 21 is irradiated with ultraviolet rays from the light source 23 from the lenticular lens 152 side (lens surface side) of the lenticular lens sheet 151. At this time, the light emitted from the light source 23 enters the lenticular lens sheet 151 as slit light 25 that has passed through the opening 241 of the mask 24. The slit light 25 is incident on the lenticular lens sheet 151 as striped slit light extending in the longitudinal direction of the lenticular lens sheet 151 (in the direction perpendicular to the paper surface in the drawing).

  The striped slit light 25 is irradiated perpendicularly to the flat surface of the lenticular lens sheet 151 from the lenticular lens 152 side while the lenticular lens sheet 151 moves in the direction in which the lenticular lens 152 is arranged.

  Thus, when the slit light 25 from the light source 23 is irradiated to the photosensitive layer 21, the uncured photosensitive layer 21 is exposed to the ultraviolet rays irradiated from the lenticular lens 152 side. At this time, the slit light 25 is condensed by the lens function of the lenticular lens 152, and the light-sensitive portion 211 of the condensed portion (hatched portion in the figure) is cured to become non-adhesive. Here, the photosensitive layer 212 in the portion (white portion in the figure) that is not condensed by the lens function remains adhesive.

  Further, since the striped slit light 25 is irradiated to the photosensitive layer 21, the non-adhesive photosensitive layer 211 is formed in a stripe shape extending in the longitudinal direction of the lenticular lens sheet 151. Therefore, the photosensitive layer 212 having adhesiveness which is the photosensitive layer 21 other than the photosensitive layer 211 is formed in a stripe shape extending in the longitudinal direction of the lenticular lens sheet 151, similarly to the photosensitive layer 211.

  As shown in FIG. 5C, the protective layer 22 on the photosensitive layer 21 is peeled off, the uncured photosensitive layer 212 having an adhesive property is colored black, and the light shielding pattern is formed of the external light absorbing layer 26. Is formed. The light shielding pattern is formed in a stripe shape like the photosensitive layer 212 because the adhesive photosensitive layer 212 is formed in a stripe shape extending in the longitudinal direction of the lenticular lens sheet 151.

  In the peeling step, a metal peeling blade 31 having a tip radius of curvature R of 5 mm as shown in FIG. 9 was used. As a coloring method for the photosensitive layer 212, there is a method in which a transfer ink layer (black) of a transfer film is superposed on the photosensitive layer 21, and the ink layer is transferred only to the photosensitive layer 212 having adhesiveness. During this transfer, the ink layer is not transferred to the non-adhesive photosensitive layer 211. Alternatively, a photosensitive film may be laminated on the light shielding pattern, and the laminated film may be cured by irradiation with ultraviolet rays, so that the ink layer on the photosensitive layer 212 does not peel off.

 For reference, FIG. 7 shows another method for manufacturing a light shielding pattern to which the present invention can be applied. (A) is process sectional drawing explaining the state of the lens sheet 151 which has the flat part 41 before forming a light shielding pattern, (b) is a lens part when forming a light shielding pattern in the lens sheet 151 with the film 42 FIG. 5C is a process cross-sectional view illustrating a state in which light is applied to the photosensitive portion 43 from the side 152. FIG. 5C is a photosensitive portion corresponding portion 44, a photosensitive portion non-corresponding portion from the opposite side of the lens portion 152 when forming a light shielding pattern 45 is a process cross-sectional view for explaining the state applied to 45, and FIG.

  After the light shielding pattern is formed, the entire surface of the photosensitive layer 21 is irradiated with ultraviolet rays to completely cure the photosensitive layer 21 (not shown). Then, a diffusion layer 27 is formed on the light shielding pattern, which diffuses light when observed from the flat surface side of the lenticular lens sheet 151 and expands the visual field region. The diffusion layer 27 also functions as a protective layer for the light shielding pattern. Further, as the diffusion layer 27, there is a material obtained by mixing a dispersion material such as silicon oxide and titanium oxide in a resin. Furthermore, the transparent resin film 28 is provided on the diffusion layer 27, and the lens sheet 30 is formed (FIG. 6).

  As described above, the lenticular lens sheet 151 of the lens sheet 30 is formed by extrusion molding without using two different types of materials. Therefore, since expensive 2P resin is not used, the production cost of the lenticular lens sheet 151 can be reduced. Further, since the lenticular lens sheet 151 can be easily formed by extrusion molding, it is possible to prevent the production equipment for the lenticular lens sheet 151 from becoming complicated.

  Furthermore, since the lenticular lens sheet 151 can be formed without using a 2P resin, it is possible to easily obtain a lenticular lens sheet 151 having good environmental stability and no warping. And since the lenticular lens sheet 151 is comprised from one type of material, a color nonuniformity can be reduced and the transparency can be improved. Further, since the lenticular lens sheet 151 is made of one kind of material, there is little crushing of the blade, and good shapeability can be easily realized.

  Furthermore, since the lenticular lens sheet 151 is formed by extrusion molding, the thickness unevenness can be reduced. Therefore, the external light absorption layer 26 can be formed with high accuracy by direct printing that easily affects the thickness unevenness, and the light shielding pattern can be accurately formed. Moreover, since the external light absorption layer 26 is formed by direct printing, a substrate film such as a transfer film used in the transfer method is not discharged as waste, so that a large environmental load can be eliminated.

  First, Examples relating to the above-described method for manufacturing a lenticular lens sheet will be described with reference to Examples 1 to 6. Comparative Example 1 and Comparative Example 2 are comparative examples with respect to Examples 1 to 6. Table 1 shows the conditions of these examples and comparative examples.

実施例１
実施例１は、樹脂１５にゴム入りＭＳ樹脂（ＭＦＲ＝１．５）を用いた場合の態様例である。本例では、ゴム入りＭＳ樹脂（ＭＦＲ＝１．５）を温度２５０℃で押し出し、エアギャップ８０ｍｍ・成形速度１０ｍ／分で、ロール径φ４００ｍｍの賦形ロールとロール径φ２９０ｍｍのゴムロール（線圧３０ｋｇ／ｃｍ時の直径方向の変形量２４０μｍ（直径の０．０８％））とを用いた。これにより、タッチ抜け等の外観欠点のない厚さ精度１８５±４μｍ・賦形率９７％の表面凹凸を転写した均一な光学シートが得られた。
実施例２
実施例２は、樹脂１５にゴム入りＭＳ樹脂（ＭＦＲ＝１．５）を用いた場合の態様例である。本例では、ゴム入りＭＳ樹脂（ＭＦＲ＝１．５）を温度２７０℃で押出し、エアギャップ９５ｍｍ・成形速度１０ｍ／分で、ロール径φ２５０ｍｍの賦形ロールとロール径φ２５０ｍｍの金属弾性ロールとを用いた。これにより、タッチ抜け等の外観欠点のない厚さ精度１８８±３μｍ・賦形率９９％の表面凹凸を転写した均一な平板光学シートが得られた。
実施例３
実施例３は、樹脂１５にＰＥＴ樹脂（固有粘度＝０．８５）を用いた場合の態様例である。本例では、ＰＥＴ樹脂（固有粘度＝０．８５）を温度２９０℃で押出し、エアギャップ８０ｍｍ・成形速度１０ｍ／分で、第２ロール１３にロール径φ４００ｍｍの賦形ロール、第１ロール１２として、ロール径φ２９０ｍｍのゴムロールを用いた。これにより、タッチ抜け等の外観欠点のない厚さ精度１７５±５μｍ・賦形率９５％の表面凹凸を転写した均一な光学シートが得られた。

Example 1
Example 1 is an example in which a rubber-containing MS resin (MFR = 1.5) is used as the resin 15. In this example, rubber-filled MS resin (MFR = 1.5) is extruded at a temperature of 250 ° C., an air gap of 80 mm, a forming speed of 10 m / min, a forming roll with a roll diameter of φ400 mm and a rubber roll with a roll diameter of φ290 mm (linear pressure of 30 kg). The amount of deformation in the diametrical direction at 240 cm / cm (0.08% of the diameter) was used. As a result, a uniform optical sheet on which the surface irregularities having a thickness accuracy of 185 ± 4 μm and a shaping ratio of 97% without any appearance defects such as missing touches was obtained.
Example 2
Example 2 is an example in which a rubber-containing MS resin (MFR = 1.5) is used as the resin 15. In this example, rubber-filled MS resin (MFR = 1.5) is extruded at a temperature of 270 ° C., and a forming roll with a roll diameter of φ250 mm and a metal elastic roll with a roll diameter of φ250 mm are formed at an air gap of 95 mm and a molding speed of 10 m / min. Using. As a result, a uniform flat optical sheet to which surface irregularities having a thickness accuracy of 188 ± 3 μm and a shaping ratio of 99% without any appearance defects such as missing touches was obtained.
Example 3
Example 3 is an example in which a PET resin (intrinsic viscosity = 0.85) is used as the resin 15. In this example, a PET resin (intrinsic viscosity = 0.85) is extruded at a temperature of 290 ° C., an air gap of 80 mm and a molding speed of 10 m / min, a second roll 13 as a forming roll having a roll diameter of φ400 mm, as a first roll 12 A rubber roll having a roll diameter of 290 mm was used. As a result, a uniform optical sheet on which surface irregularities having a thickness accuracy of 175 ± 5 μm and a shaping ratio of 95%, free from defects in appearance such as missing touches, was obtained.

Next, examples regarding the formation of the light shielding layer on the lens sheet described above will be described with reference to examples 4 and 5.
Example 4
The photosensitive layer 21 was formed by applying an ultraviolet photosensitive resin to the anti-lens portion (the flat surface portion opposite to the lens portion) of the lenticular lens sheet 151 obtained in Examples 1 to 3 using a gravure roll. Then, the ultraviolet-ray UV irradiation was carried out from the lens part side, and the non-adhesion part (exposure part, the photosensitive part 211) and the adhesion part (non-exposure part, the photosensitive part 212) were formed.

Next, BS (Black Stripe) printing was performed by a direct coating method in which a black paint and a transfer film coated with the black paint were attached to the adhesive portion, thereby forming an external light absorption layer 26, and a lenticular lens sheet A was produced. In the peeling step, a metal peeling blade 31 having a tip radius of curvature R of 4 mm as shown in FIG. 9 was used.
Example 5
A lenticular lens sheet A was produced in the same manner as in Example 4 except that a sheet made of polyethylene fluoride was attached to the tip of the metallic peeling blade 31 in the peeling step, and the curvature radius R of the tip was changed to 5 mm. . At this time, the dynamic friction coefficient of the polyfluoroethylene sheet at the tip of the peeling blade 31 was measured and found to be 0.1.
Example 6
In the peeling step, a lenticular lens sheet A was produced in the same manner as in Example 4 except that the peeling blade 31 was removed and a rubber roller having a diameter of 40 mm was attached as a peeling roll 35 instead of this.
Comparative Example 1
In the transfer film peeling step, a lenticular lens sheet B was produced in the same manner as in Example 4 except that a metallic peeling blade 31 having a radius of curvature R at the tip as shown in FIG.

  In order to compare the appearances of the lenticular lens sheets A of Examples 4 to 6 and the lenticular lens sheet B of Comparative Example 1 with each other, the respective lenticular lens sheets A and B are set on a projection television to form a rear projection screen. From a distance of 1.5 m in the bright room, 10 screens were randomly selected to conduct an external appearance comparison inspection of each screen.

  As a result, regarding the screen according to Comparative Example 1, all ten observers determined that “the streaks are conspicuous”. On the other hand, with respect to the screen according to Example 4, all 10 observers determined that “the stripe pattern is not noticeable and there is no problem”. Furthermore, with respect to the screens of Examples 5 and 6, all 10 observers determined that “the streak pattern is not noticeable and the appearance is particularly good”.

Next, Example 7 and Comparative Example for manufacturing a front plate by transferring and peeling an antireflection film using a 100 μm thick PET film as a base film on the surface of a 2 mm thick transparent sheet made of MS resin. 2 is evaluated.
Example 7
In the peeling step, a front plate A with an antireflection film was produced using a metallic peeling blade 31 having a tip radius of curvature R of 4 mm as shown in FIG.
Comparative Example 2
In Example 7, a front plate B with an antireflection film was produced in the same manner as in Example 7 except that the radius of curvature R at the tip of the peeling blade 31 was 6 mm.

In order to compare the appearances of the front plate A of Example 7 and the front plate B of Comparative Example 2, the front plates A and B are set on a projection television to form a front plate, and 1.5 m in the bright room. An external appearance comparison test was conducted by 10 randomly selected observers from a distance.
As a result, with respect to the front plate B of Comparative Example 2, all 10 observers determined that “the streaks are conspicuous”. On the other hand, with respect to the front plate A of Example 7, all 10 observers determined that “the stripe pattern was not noticeable and there was no problem”.

It is a schematic diagram showing the whole composition of the lens sheet (optical sheet) manufacturing device in the present invention. It is a schematic diagram which shows the manufacturing apparatus of the lenticular lens sheet in this invention. The elastic roll in this invention is shown, (a) is a schematic sectional drawing explaining the state before an elastic roll is crushed, (b) is a schematic sectional drawing explaining the state where the elastic roll was crushed. The elastic roll in this invention is shown, (a) is a schematic sectional drawing explaining the state before an elastic roll bends, (b) is a schematic sectional drawing explaining the state in which the elastic roll bent. The manufacturing method of the light-shielding pattern in this invention is shown, (a) is process sectional drawing explaining the state before forming a light-shielding pattern, (b) is process sectional drawing explaining the state at the time of forming a light-shielding pattern, ( (c) is process sectional drawing explaining the state after forming the light shielding pattern. It is sectional drawing which shows the lens sheet in this invention. FIGS. 4A and 4B show another method for manufacturing a light shielding pattern according to the present invention, wherein FIG. 4A is a process cross-sectional view illustrating a state of a lens sheet before forming a light shielding pattern, and FIG. Step cross-sectional view explaining a state where light is applied from the side, (c) is a step cross-sectional view explaining a state where light is applied from the side opposite to the lens portion when forming the light-shielding pattern, and (d) is after forming the light-shielding pattern It is process sectional drawing explaining the state of this. It is the schematic which shows the process of peeling a base film from the lenticular lens sheet which transferred the light shielding layer in this invention. It is the schematic which expanded the peeling blade vicinity in FIG. The mechanism in which zipping occurs in the process of peeling the substrate film from the lenticular lens sheet to which the light shielding layer has been transferred is shown, (a) is a schematic diagram for explaining the state before the peeling point moves, (b) It is a schematic diagram for demonstrating the state after a peeling point moved. It is the schematic for demonstrating the Example of another peeling apparatus in this invention. It is sectional drawing which shows the conventional lens sheet.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Manufacturing apparatus 110 Extruder 160 Film 15 Resin 13 2nd roll 12 1st roll 151 Lenticular lens sheet 21 Photosensitive layer 211 Photosensitive part 212 Photosensitive part 26 External light absorption layer 31 Peeling blade 35 Peeling roll

Claims (9)

A method of manufacturing an optical sheet such as a lenticular lens sheet or a prism lens sheet used in a rear projection screen, and the method of manufacturing the optical sheet includes:
A step of forming an optical sheet main body having a lens portion; a step of forming a photosensitive layer on a flat surface opposite to the lens portion of the optical sheet main body; and a step from the lens portion side of the optical sheet main body to the photosensitive layer. Irradiating light such as ultraviolet rays, and forming a light-shielding pattern having a cured portion and an uncured portion based on light collection by the lens portion,
The step of forming the light shielding pattern includes disposing a transfer film having a light shielding layer on the photosensitive layer, transferring the light shielding layer to an uncured portion of the photosensitive layer, and then providing a peeling blade or a driving mechanism with a diameter of 100 mm. A method for producing an optical sheet, wherein the transfer film is peeled off by the following peeling roll to form a light shielding pattern.   An apparatus used when manufacturing an optical sheet such as a lenticular lens sheet or a prism lens sheet, and has a means for attaching the transfer film to the optical sheet body to transfer the functional film and then peeling the transfer film. The peeling means includes a peeling blade, and the radius of curvature of the tip of the peeling blade is 5 mm or less.   The apparatus for producing an optical sheet according to claim 2, wherein the dynamic friction coefficient of the material of the tip surface of the peeling blade is 0.2 or less.   4. The optical sheet manufacturing apparatus according to claim 2, wherein the material of at least the surface of the tip of the peeling blade contains at least one of polyolefin, polyfluorinated ethylene, or a copolymer thereof. .   An apparatus used when manufacturing an optical sheet such as a lenticular lens sheet or a prism lens sheet, and has a means for attaching the transfer film to the optical sheet body to transfer the functional film and then peeling the transfer film. And the said peeling means contains a peeling roll, The diameter of this peeling roll is 100 mm or less, The manufacturing apparatus of the optical sheet characterized by the above-mentioned.   The optical sheet manufacturing apparatus according to claim 5, wherein the peeling roll includes a drive mechanism. The optical sheet comprises a lenticular lens sheet used for a rear projection screen, and
Means for forming a lenticular lens sheet main body having a lens part; means for forming a photosensitive layer on a flat surface opposite to the lens part of the lenticular lens sheet main body; and Means for irradiating light from the lens unit side, and forming a light-shielding pattern having a cured portion and an uncured portion based on light collection by the lens unit;
The light shielding pattern forming means includes disposing a transfer film having a light shielding layer on the photosensitive layer, transferring the light shielding layer to an uncured portion of the photosensitive layer, and then peeling the transfer film to form a light shielding pattern. The optical sheet manufacturing apparatus according to claim 2, wherein the optical sheet manufacturing apparatus is formed.   8. The optical sheet manufacturing apparatus according to claim 7, wherein the light is ultraviolet light, and the photosensitive layer is an ultraviolet curable photosensitive resin. 9. The optical sheet according to claim 2, wherein the optical sheet is a lenticular lens sheet and is manufactured using the optical sheet manufacturing apparatus according to any one of claims 2 to 8.

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