JP2007007918A - Manufacturing method of laminate - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a laminate capable of easily obtaining the laminate uniformized in its external shape even in a case that a plurality of layers largely different in characteristics are laminated. <P>SOLUTION: A Fresnel frame member 112 made of a resin is arranged so as to surround the outer periphery of the edge face of a Fresnel substrate layer 111 made of glass. Then, a Fresnel lens layer 113 is bonded through a Flesnel adhesive layer 114 so as to cover both of the Freesnel substrate layer 111 and the Fresnel frame member 112 to form a Flesnel lens sheet 110. Finally, the Fresnel frame member 112 is cut to set the external shape of the laminate to a desired shape. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for producing a laminated body in which a plurality of layers such as a transmission screen, an anti-scattering glass, and a solar cell module are laminated.

A transmissive screen will be described as a representative example of the laminate.
Conventionally, this type of transmissive screen is used in a rear projection type display device that projects and displays image light from behind the screen, and is used by enlarging and projecting the image light and displaying it on the observation side.
This transmissive screen generally includes a Fresnel lens sheet that refracts image light projected from a light source (for example, a liquid crystal projector) to the observation side so as to be substantially parallel light, and a lenticular lens that diffuses this image light. Used in combination with a sheet or the like.
The Fresnel lens sheet and the lenticular lens sheet are formed as an integral sheet by extrusion molding, or are formed by laminating optical elements such as lenses on a plastic substrate such as acrylic resin or polycarbonate resin.

However, the thickness and size of a plastic substrate may change due to environmental changes such as temperature and humidity. For this reason, the sheet may be deformed and warped, and a float may be generated between the Fresnel lens sheet and the lenticular lens sheet. When image light is projected onto the transmissive screen in such a state, there is a problem that the image quality is remarkably deteriorated, such as defocusing, deterioration of color reproducibility, double image, and image distortion.
In particular, in a thin rear projection television, since the incident angle of the image light on the transmissive screen is large, there is a problem that slight warping or floating generated in the transmissive screen has a great influence on the image quality.
Further, when the transmission type screen is enlarged, there is a problem that image deterioration due to warping and floating caused by environmental changes becomes more conspicuous than a small one, and there is a problem that it is easily bent due to its own weight.

Therefore, a transmission type screen using a glass substrate (hereinafter referred to as a glass substrate) that is resistant to changes in temperature and humidity and does not warp due to environmental changes has been developed (for example, Patent Document 1).
Patent Document 1 discloses a lenticular lens layer (referred to as “Fresnel lens plate” in Patent Document 1) and a glass substrate mixed with a diffusing material to have a diffusion effect. A transmissive screen is disclosed in which a lenticular lens sheet (described as “lenticular lens plate” in Patent Document 1) in which a “lenticular lens sheet” is stacked is combined.
According to the transmission type screen of Patent Document 1, since the Fresnel lens plate and the lenticular lens plate can be combined in close contact to maintain the close contact state, deterioration of image quality can be prevented.

By the way, glass substrates used for transmission screens generally use blue plate glass, alkali glass, non-alkali glass, etc., and as those with special functions added, heat resistant glass, tempered glass, There are semi-tempered glass.
Further, in recent years, display products are becoming thinner and larger, and the glass substrate used as a component is also becoming thinner and larger.
For this reason, the glass substrate needs to be strengthened and subjected to safety measures. For example, the end face thereof is subjected to C chamfering or R chamfering.

  However, even if the end surface of the glass substrate is reinforced by C chamfering or R chamfering, the end surface may be damaged due to bending or contact with other members during handling and cracking. There was a problem that there was.

In addition, in a transmission screen having a glass substrate, materials having greatly different characteristics such as a glass substrate and a Fresnel lens sheet or a lenticular lens sheet are bonded together, and it is difficult to cut them to a required size. It was.
If it is only a glass substrate or only a lens sheet, it is easy to cut each. For example, the glass substrate can be easily cut by using a diamond cutting tool and the lens sheet by using a blade or the like. However, when a lens sheet, an anti-scattering film, or the like is bonded to a glass substrate, the cutting method is limited because the characteristics possessed by each lens are different. For example, Patent Document 2 discloses a method using a water jet. There is also a method using a diamond grindstone. However, these cutting methods have a problem in that a large amount of water is used and a large amount of polishing waste is generated, so that the lens sheet and the film may be deteriorated or poor adhesion may occur. In addition, the cutting speed is very slow and the productivity is poor.

Further, the method of cutting separately (Patent Document 3) has a problem that it is necessary to accurately perform alignment at the time of the second cutting. In addition, there is a problem in that productivity is poor because cutting is performed twice.
In addition, the laminated body such as the anti-scattering glass and the solar cell module has the same problem regarding cutting.

JP 2002-357868 A JP 60-180942 A JP 7-291648 A

  The subject of this invention is providing the manufacturing method of the laminated body which can obtain easily the laminated body with which the external shape was equal even if it is a case where the several layer from which a characteristic differs greatly.

The present invention solves the above problems by the following means. In addition, in order to make an understanding easy, although the code | symbol corresponding to the Example of this invention is attached | subjected and demonstrated, it is not limited to this.
The invention of claim 1 includes a substrate layer (111, 121, 211, 311, 411) formed of a single layer or a plurality of different layers, and a cover layer (113, 123) laminated on the substrate layer. , 125, 213, 215, 313, 413), and a frame member (112, 122, 212, 312, 412) is installed so as to cover the outer peripheral edge of the substrate layer. An adhesive layer (114, 124, 214) on at least one surface of the substrate layer and the frame member so as to cover both the substrate layer and the frame member after the frame member arranging step and the frame member arranging step. , 314, 414), and after the bonding step, the frame member and the cover layer are cut at a position where the frame member and the cover layer are bonded. Not necessary A cutting step of the dimensions, a method for producing a laminate having a.
According to a second aspect of the present invention, in the method for manufacturing a laminate according to the first aspect, the adhesive used for the adhesive layer (114, 124, 214, 314, 414) has fluidity in a state before curing. In the bonding step, the substrate layer (111, 121, 211, 311, 411) and the frame member (112, 122, 212, 312, 412) exist between the cover layer. It is the manufacturing method of the laminated body which has the adhesive material extrusion process which extrudes an unnecessary part in the said adhesive material to the outer peripheral side of the said frame member.
The invention of claim 3 is the method for manufacturing a laminate according to claim 1 or claim 2, wherein the thickness of the substrate layer (111, 121, 211, 311, 411) in the stacking direction and the frame member (112, 112). 122, 212, 312, 412) is a method for manufacturing a laminate, characterized in that the thickness in the stacking direction is substantially equal.
Invention of Claim 4 is the manufacturing method of the laminated body of any one of Claim 1- Claim 3, In the said cover layer (113,123,125,213,215,313,413), It is a manufacturing method of the laminated body characterized by being laminated | stacked on both surfaces of the said board | substrate layer (111,121,211,311,411) and the said frame member (112,122,212,312,412).
According to a fifth aspect of the present invention, in the laminate manufacturing method according to any one of the first to fourth aspects, the frame member (112, 122, 212, 312, 412) is a plastic resin or rubber. It is formed by these, It is a manufacturing method of the laminated body characterized by the above-mentioned.
Invention of Claim 6 is a manufacturing method of the laminated body of any one of Claim 1- Claim 5, In the said adhesion | attachment process, said board | substrate layer (111, 121, 211, 311 and 411) and It is a manufacturing method of the layered product characterized by adhering between the frame members (112, 122, 212, 312, 412) by the adhesive layers (114, 124, 214, 314, 414).
The invention according to claim 7 is the method for manufacturing a laminate according to any one of claims 1 to 6, wherein the substrate layer (111, 121, 211, 311, 411) is made of glass or translucent. It is the manufacturing method of the laminated body characterized by being formed with the property ceramics.
According to an eighth aspect of the present invention, in the method for manufacturing a laminate according to the seventh aspect, at least a portion of the frame member (112, 122, 212) facing the substrate layer (111, 121, 211) absorbs light. It is the manufacturing method of the laminated body characterized by having an effect | action.

According to the present invention, the following effects can be obtained.
(1) At least one of the substrate layer and the frame member so as to cover both the substrate layer and the frame member after the frame member arranging step of installing the frame member so as to cover the outer peripheral end of the substrate layer and the frame member arranging step. A bonding step of laminating a cover layer on the surface via an adhesive layer, and after the bonding step, the frame member and the cover layer are cut at the position where the frame member and the cover layer are bonded to obtain the required external dimensions. Since it has a cutting process, even if the characteristics of the substrate layer and the cover layer are greatly different, it can be easily cut.
(2) Since the adhesion process includes an adhesive material extrusion process for extruding unnecessary portions of the adhesive material existing between the substrate layer and the frame member and the cover layer to the outer peripheral side of the frame member, The substrate layer and the frame member can be reliably bonded to the cover layer.
(3) Since the thickness of the substrate layer in the stacking direction is substantially equal to the thickness of the frame member in the stacking direction, the cover layer can be easily stacked.
(4) Since the cover layer is laminated on both surfaces of the substrate layer and the frame member, it is possible to suppress the scattering of fragments when the substrate layer is damaged.
(5) Since the frame member is formed of plastic resin or rubber, it is light and easy to manufacture while ensuring the necessary strength.
(6) In the bonding step, the bonding between the substrate layer and the frame member is also performed by the bonding layer, so that the frame member can be more reliably fixed to the substrate layer. In addition, the substrate layer and the frame member can be fixed at the same time when the cover layer is formed, thereby facilitating manufacture.
(7) Since the substrate layer is formed of glass or translucent ceramics, the substrate layer has high rigidity and high flatness can be ensured. In addition, high environmental resistance can be obtained.
(8) Since at least the portion of the frame member that faces the substrate layer has a light absorption function, stray light that repeats reflection in the substrate layer can be reduced.

  An object of the present invention is to provide a method for manufacturing a laminate that can easily obtain a laminate having a uniform outer shape even when a plurality of layers having greatly different characteristics are laminated. This was realized by cutting the frame member arranged in the box.

FIG. 1 is a cross-sectional view of a rear projection television using the transmission screen of the first embodiment.
The rear projection television 1 is a rear projection display device including a light source unit 21, a mirror unit 31, a transmission screen 100, and the like. This rear projection television 1 is image light projected from a single-tube light source unit 21 using a DMD (Digital Micromirror Device) provided on the opposite side of the observation screen side (outgoing side) of the transmissive screen 100. L is reflected by the mirror unit 31 and projected onto the transmission screen 100 for display.
FIG. 2 is a perspective view illustrating the transmission screen according to the first embodiment.
As shown in FIG. 2, the transmissive screen 100 of Example 1 is provided on the Fresnel lens sheet 110 provided on the incident side (light source side) of the image light L and on the emission side (observation surface side) of the image light L. The lenticular lens sheet 120 is combined, and these are combined to form a set of transmission screens, which are arranged on the image plane of the image light L.

FIG. 3 is a diagram schematically showing the layer configuration of the transmission screen of Example 1. As shown in FIG.
Video light L indicated by an arrow in the figure enters the transmission screen 100 from above in the figure and exits downward in the figure.

(Fresnel lens sheet)
First, the Fresnel lens sheet 110 will be described.
The Fresnel lens sheet 110 has a Fresnel substrate layer 111, a Fresnel frame member 112, a Fresnel lens layer 113, and a Fresnel adhesive layer 114, and is a laminate that is disposed on the incident side of the transmission screen 100.
The Fresnel substrate layer 111 is a highly transparent and highly rigid substrate layer, and is a glass plate with a thickness of 2 mm formed of silicate glass. The Fresnel substrate layer 111 has a light transmittance of 90% or more in a wavelength band of 400 to 700 nm.

The Fresnel frame member 112 is an acrylic resin frame member that covers the outer peripheral edge of the Fresnel substrate layer 111, and has a thickness of 2 mm, which is the same as that of the Fresnel substrate layer 111. Further, the Fresnel frame member 112 is made of a black resin and has a light absorption function.
The Fresnel lens layer 113 is a cover layer that is laminated via the Fresnel adhesive layer 114 on the emission side of the Fresnel substrate layer 111 and the Fresnel frame member 112 so as to cover both the Fresnel substrate layer 111 and the Fresnel frame member 112. .
The Fresnel lens layer 113 has a Fresnel lens shape formed on the exit side, and functions as a Fresnel lens that refracts the image light L incident from the entrance side in a predetermined direction and emits the substantially parallel light to the exit side.

The Fresnel lens layer 113 heats a Fresnel lens molding mold (not shown) having a reverse shape of a Fresnel lens, applies an ultraviolet curable resin to the mold surface, and the temperature of the applied ultraviolet curable resin. The substrate layer (not shown) is pressure-laminated on the ultraviolet curable resin filled in the mold while the resin is kept, and the resin is cured by irradiating with ultraviolet rays, and is peeled off from the mold. The ultraviolet curable resin is not particularly limited, but urethane acrylate, epoxy acrylate and the like are preferable.
The Fresnel adhesive layer 114 is a layer that bonds the Fresnel substrate layer 111 and the Fresnel frame member 112 to the Fresnel lens layer 113, and is formed of an ultraviolet curable acrylic resin that is cured by irradiating ultraviolet rays, and has a thickness of 100 μm.
The Fresnel adhesive layer 114 is also filled between the Fresnel substrate layer 111 and the Fresnel frame member 112, and also has a role of adhering them.

(Lenticular lens sheet)
Next, the lenticular lens sheet 120 will be described.
The lenticular lens sheet 120 includes a lenticular substrate layer 121, a lenticular frame member 122, a lenticular lens layer 123, a lenticular adhesive layer 124, and a front layer 125. The lenticular lens sheet 120 is a diffusing optical sheet that refracts and diffuses image light L. It is a laminate that is disposed on the exit side of the screen 100.

The lenticular substrate layer 121 is a light-transmitting and highly rigid substrate layer, and is a glass plate having a thickness of 2 mm formed of silicate glass, like the Fresnel substrate layer 111. Like the Fresnel substrate layer 111, the lenticular substrate layer 121 has a light transmittance of 90% or more in the wavelength band of 400 to 700 nm.
The lenticular frame member 122 is an acrylic resin frame that covers the outer peripheral edge of the lenticular substrate layer 121, and has a thickness of 2 mm, which is the same as that of the lenticular substrate layer 121. The lenticular frame member 122 is formed of a black resin.

The lenticular lens layer 123 is a cover on the incident side that is laminated on the incident side of the lenticular substrate layer 121 and the lenticular frame member 122 via the lenticular adhesive layer 124 so as to cover both the lenticular substrate layer 121 and the lenticular frame member 122. Is a layer.
The lenticular lens layer 123 has a lenticular lens shape formed on the incident side, and has an action of diffusing incident video light.
The lenticular lens layer 123 is formed by arranging a plurality of unit lenses having a diffusion effect in the horizontal direction. The unit lens has a shape that protrudes toward the emission side having a substantially elliptical cross section, and refracts at least part of incident light.
The light absorbing portion 123a extends in the vertical direction of the transmissive screen 100 in a region where the image light on the emission side surface of the lenticular lens layer 123 does not pass, and is arranged in a plurality of stripes in the horizontal direction. Yes.

The lenticular adhesive layer 124 is a layer that bonds the lenticular substrate layer 121, the lenticular frame member 122, and the lenticular lens layer 123, and is formed of an ultraviolet curable acrylic resin that is cured by irradiating ultraviolet rays. The thickness between the lenticular frame member 122 and the lenticular lens layer 123 is 100 μm.
The lenticular adhesive layer 124 also has a role of adhering the lenticular substrate layer 121 and the lenticular frame member 122 to the front layer 125 described later, and between the lenticular substrate layer 121 and the lenticular frame member 122 and the front layer 125. The thickness at is also 100 μm.
The lenticular adhesive layer 124 is also filled between the lenticular substrate layer 121 and the lenticular frame member 122, and also has a role of adhering them.
The front layer 125 is a layer that becomes the most observer-side surface of the transmissive screen, and is formed of polyethylene terephthalate resin to a thickness of 188 μm. The front layer 125 has functions such as diffusion, antireflection, antiglare, coloring (Tint), dimming (ND), ultraviolet absorption, antistatic, antifouling, sensor, and hard coat as necessary. It may be given.

Next, a method for manufacturing the Fresnel lens sheet 110 of this example will be described.
4 and 5 are cross-sectional views showing a method for manufacturing the Fresnel lens sheet 110. FIG.
6 and 7 are perspective views showing a method for manufacturing the Fresnel lens sheet 110. FIG.
In addition, the process 1-the process 8 in FIG.4 and FIG.5 have shown the same process corresponding to the process 1-the process 8 in FIG.6 and FIG.7, respectively.

(Process 1)
The Fresnel substrate layer 111 and the Fresnel frame member 112 are arranged on the work table T (frame member arrangement step). At this time, the Fresnel substrate layer 111 is disposed in the hollow portion of the Fresnel frame member 112. Further, since the thickness of the Fresnel substrate layer 111 and the Fresnel frame member 112 are both equal to 2 mm, the top surfaces are aligned. The work table T is preliminarily applied with a release agent.

(Process 2)
An ultraviolet curable acrylic resin G1 to be the Fresnel adhesive layer 114 is applied to the entire upper surfaces of the Fresnel substrate layer 111 and the Fresnel frame member 112 by the multiple nozzles N1.

(Process 3)
The acrylic resin has already been applied to the upper surfaces of the Fresnel substrate layer 111 and the Fresnel frame member 112 in Step 2, and the multiple nozzles N1 are provided near one end of the Fresnel substrate layer 111 and the Fresnel frame member 112 by the nozzle N2. Further, the same acrylic resin G2 as that applied in the step 2 is additionally applied in a direction substantially orthogonal to the direction applied. In addition, the position where the acrylic resin G2 is additionally applied in Step 3 is not limited to the position shown in the figure, and an optimal position may be selected by performing a preliminary experiment or the like.
If the acrylic resins G1 and G2 applied in these steps 2 and 3 are applied in a sufficiently large amount so as to be extruded and protruded in the subsequent step 5, they can be bonded without gaps.

(Process 4)
A Fresnel lens layer 113 formed separately is loaded on the surface to which the acrylic resins G1 and G2 are applied. Here, the outer shape when viewed from the normal direction of the sheet surface of the Fresnel lens layer 113 to be stacked is preferably larger than that of the Fresnel substrate layer 111, and is preferably substantially the same as the outer shape of the Fresnel frame member 112. More preferably, the outer shape of the Fresnel frame member 112 is desirably larger.

(Process 5)
After the Fresnel lens layer 113 is loaded on the acrylic resins G1 and G2, the acrylic resin G1 and G2 are uniformly extended by the nip roller R together with the work table T, and excess resin and air are removed from the acrylic resins G1 and G2. Extrusion to the outer peripheral side of the Fresnel frame member 112 (adhesive extruding step).
Then, the acrylic resins G1 and G2 are cured by irradiating ultraviolet rays as they are, and the bonding process shown in Steps 2 to 5 is completed, and a rough shape of the Fresnel lens sheet 110 is formed.

(Step 6)
When the acrylic resins G1 and G2 are sufficiently cured, they are removed from the work table T. At this time, since the release agent is applied to the work table T, the Fresnel lens sheet 110 can be removed without difficulty.

(Step 7)
In the Fresnel lens sheet 110 removed in Step 6, a part of the adhesive layer protrudes from the outer peripheral portion, and the Fresnel lens layer 113 protrudes greatly. Therefore, it is cut into a required size in this step (cutting step). At this time, the cutting position is a position where the Fresnel frame member 112 is cut. By doing so, it is not necessary to cut the Fresnel substrate layer 111 made of glass which is difficult to cut, and the Fresnel lens layer 113 which is thin and difficult to cut can be easily cut.

(Process 8)
Unnecessary portions are cut in step 7 to complete the Fresnel lens sheet 110.
The Fresnel frame member 112 left after the cutting remains in a form covering the outer periphery of the Fresnel substrate layer 111, and can protect the Fresnel substrate layer 111.

  The lenticular lens sheet 120 can also be produced in the same manner as the Fresnel lens sheet 110, except that the lenticular lens layer 123 and the front layer 125, which are cover layers, are bonded to both sides of a glass lenticular substrate layer 121. .

Here, the thickness of the Fresnel substrate layer 111 and the Fresnel frame member 112 will be described. Here, the Fresnel substrate layer 111 and the Fresnel frame member 112 will be described, but the relationship between the lenticular substrate layer 121 and the lenticular frame member 122 is the same.
In this embodiment, both the Fresnel substrate layer 111 and the Fresnel frame member 112 have the same thickness (2 mm). The reason is that the following problems occur when the Fresnel substrate layer 111 and the Fresnel frame member 112 are greatly different in thickness.

(Problem when the Fresnel frame member 112 is thicker than the Fresnel substrate layer 111)
If the Fresnel frame member 112 is thicker than the Fresnel substrate layer 111, when the acrylic resins G1 and G2 are pushed out, bubbles mixed in the acrylic resins G1 and G2 hit the Fresnel frame member 112 and the bubbles do not escape.
Further, the acrylic resins G1 and G2 in the vicinity where the Fresnel substrate layer 111 and the Fresnel frame member 112 are in contact with each other increase, and the Fresnel adhesive layer 114 in that portion becomes thick, which impairs the planarity of the Fresnel lens sheet 110.

(Problem when the Fresnel frame member 112 is thinner than the Fresnel substrate layer 111)
If the Fresnel frame member 112 is thinner than the Fresnel substrate layer 111, bubbles are newly generated at the level difference between the Fresnel substrate layer 111 and the Fresnel frame member 112 when the acrylic resins G1 and G2 are pushed out.
In addition, the adhesion between the Fresnel frame member 112 and the Fresnel lens layer 113 becomes incomplete, and peeling occurs.

(Allowable difference between substrate layer thickness and frame member thickness)
As described above, the thicknesses of the substrate layers such as the Fresnel substrate layer 111 and the lenticular substrate layer 121 and the frame members such as the Fresnel frame member 112 and the lenticular frame member 122 desirably match each other. However, there may be cases where it is desired to use different thicknesses due to parts procurement. Therefore, to what extent the difference in thickness between the substrate layer and the frame member is allowed was determined by experiment.
Specifically, an experiment was conducted in which members corresponding to frame members having different thicknesses were prepared and the cover member was bonded to a substrate layer having a constant thickness. As the substrate layer, a square glass plate having a thickness of 3 mm and a 50 cm square was used.
Judgment of bubbles is ○ when the number of bubbles having a radius of 0.2 mm or less is 5 or less, Δ when the number of bubbles having a radius of 0.2 mm or less is 5 to 10, and 10 bubbles having a radius of 0.2 mm or less. The case above and the case where there were bubbles larger than 0.2 mm in radius were determined as x.
Moreover, regarding peeling, the case where it peeled off was set to x, and the case where there was no peeling was set to (circle).
Each measurement was performed three times. The results are shown in Table 1.
From the results of this experiment, it can be said that the difference in thickness between the base material layer and the frame member is desirably ± 0.4 mm or less.

According to the present embodiment, since both the Fresnel lens sheet 110 and the lenticular lens sheet 120 have a highly rigid glass substrate layer (Fresnel substrate layer 111, lenticular substrate layer 121), they are stable regardless of environmental changes. High flatness.
Moreover, since the outer periphery of the Fresnel substrate layer 111 and the lenticular substrate layer 121 is surrounded by the Fresnel frame member 112 and the lenticular frame member 122, the Fresnel substrate layer 111 and the lenticular substrate layer 121 can be prevented from being damaged.
Further, since the cutting is performed at the position of the Fresnel frame member 112 (lenticular frame member 122) at the time of manufacture, the Fresnel adhesive layer 114 (lenticular adhesive layer 124) can be protruded and cured, making the transmission screen easier. Can be manufactured at low cost.

FIG. 8 is a cross-sectional view of a rear projection television using the transmission screen of the second embodiment.
The rear projection television 2 is a rear projection display device including a light source unit 22, a mirror unit 32, and a transmissive screen 200. The light source unit 22 is a single tube type light source using DMD, and projects the image light L from below the transmissive screen 200. Therefore, the incident angle at which the image light L enters the transmission screen 200 is larger than that of the rear projection television 1 of the first embodiment.

FIG. 9 is a diagram illustrating a transmission screen according to the second embodiment.
FIG. 10 is a diagram schematically showing the layer configuration of the transmission screen of Example 2. As shown in FIG.
The transmission screen 200 is a laminated body including a prism substrate layer 211, a prism frame member 212, a prism layer 213, a prism adhesive layer 214, a horizontal diffusion layer 215, and an omnidirectional diffusion layer 216.
The transmissive screen 200 is a transmissive screen that emits image light projected from the light source unit 22 in an observable state to the observer side, and deflects the emission direction of the image light projected from the light source unit 22. Light is diffused and emitted in the horizontal direction.

  Here, in the rear projection television 2 in the present embodiment, the entire apparatus is thinned by projecting image light on the transmission screen 200 from an oblique direction. Accordingly, light is incident at a considerably large angle (an angle of about 70 degrees or more at the upper end portion) at any position on the transmissive screen 200. Therefore, in this embodiment, a prism layer 213 is provided instead of the Fresnel lens used in the first embodiment.

FIG. 11 is a cross-sectional view for explaining the operation of the prism layer 213.
As shown in FIG. 9, the prism layer 213 includes a plurality of unit prisms 213c having an incident surface 213a on which the image light L is incident and a total reflection surface 213b that totally reflects at least part of the light incident from the incident surface 213a. Further, they are arranged concentrically from the center P of the concentric circle outside the transmission screen 200.
Each unit prism shape 213 c refracts and totally reflects the image light L projected from the light source unit 22 and incident at a large angle from an oblique direction, and travels in a direction substantially perpendicular to the sheet surface of the transmissive screen 200. Note that the width (lens pitch) of each unit prism shape 213c needs to be about 1 mm or less, and preferably about 0.1 mm so that a large number of unit prism shapes 213c are not visually recognized on the screen. In this embodiment, it is 0.1 mm.

  Here, the incident angle of the image light L incident on each unit prism shape 213c differs depending on the position of each unit prism shape 213c on the plane of the transmission screen 200, and according to such a change in incident angle. Thus, the shape of each unit prism shape 213c is changed.

Returning to FIG. 10, the horizontal diffusion layer 215 is a layer that diffuses the image light in the horizontal direction, and includes a unit trapezoidal shape 215 a and a light absorbing portion 215 b.
The unit trapezoidal shape 215a has a substantially trapezoidal cross-sectional shape in the horizontal direction, and its longitudinal direction extends in the vertical direction. The unit trapezoidal shape 215a has a function of totally reflecting light by the surface corresponding to the hypotenuse and diffusing the light. By arranging a large number of the unit trapezoidal shapes 215a side by side in the horizontal direction, the light diffusing portion is arranged. Is formed.

The light absorbing portion 215b is a light shielding portion formed by filling a V-shaped groove portion formed between the unit trapezoidal shapes 215a with light-absorbing ink. This light absorbing portion 215b has an effect of removing external light mainly traveling from the observation side in the horizontal direction. The light absorbing portion 215b may not be filled in the V-shaped groove formed between the unit trapezoidal shapes 215a, and is formed on the surface corresponding to the hypotenuse of the unit trapezoidal shape 215a. Just do it.
Note that the cross-sectional shape of the unit trapezoidal shape 215a in the present embodiment is a straight line in the portion corresponding to the trapezoid hypotenuse, but is not limited to this, for example, it may be a shape combining a plurality of straight lines, or a curved line It may be.

The prism substrate layer 211 is a glass layer corresponding to the Fresnel substrate layer 111 and the lenticular substrate layer 121 in the first embodiment.
The prism frame member 212 is an acrylic resin frame corresponding to the Fresnel frame member 112 and the lenticular frame member 122 in the first embodiment, and covers the outer peripheral end of the prism substrate layer 211.
The prism adhesive layer 214 is the same layer as the Fresnel adhesive layer 114 and the lenticular adhesive layer 124 in the first embodiment, and bonds the prism substrate layer 211 and the prism layer 213 together with the prism substrate layer 211 and the horizontal diffusion layer 215. Is glued. The prism adhesive layer 214 also bonds the prism substrate layer 211 and the prism frame member 212.
The non-directional diffusion layer 216 is a layer in which a sheet formed by mixing glass terephthalate resin with glass beads as a diffusing material substantially uniformly is joined to the most emitting side of the transmissive screen 200. The glass beads mixed in the omnidirectional diffusion layer 216 have a diameter of 1 μm or more so that diffusion does not depend on the wavelength of light. It should be noted that functions such as antireflection, antiglare, antistatic, antifouling, and hard coating may be imparted to the exit side surface of the non-directional diffusion layer 216 as necessary.
The transmissive screen 200 can be manufactured in the same manner as the transmissive screen 100 of Example 1, although the prism layer 213 and the horizontal diffusion layer 215 are formed on both sides of the prism substrate layer 211.

  Since the rear projection television 2 of the second embodiment has a large incident angle of the image light L, the influence of image degradation caused by slight warping or floating of the transmissive screen 200 is larger than that of the rear projection television 1 of the first embodiment. And very big. In particular, the farther from the light source unit 22, such as the upper side of the transmissive screen, the greater the influence on the image quality due to the floating of the transmissive screen.

However, since the transmission type screen 200 has a prism substrate 213 and a horizontal diffusion layer 215 that are laminated on both sides of a prism substrate layer 211 made of glass having high rigidity, the warp due to changes in the environment such as temperature and humidity. It does not easily float or bend due to its own weight, and can maintain high flatness. Therefore, even when the incident angle of the video light L is large as in the rear projection television 2, a high-quality image can be provided to the observer.
Moreover, since the outer periphery of the prism substrate layer 211 is surrounded by the prism frame member 212 as in the first embodiment, the prism substrate layer 211 can be prevented from being damaged.
Further, since the cutting is performed at the position of the prism frame member 212 at the time of manufacture, the prism adhesive layer 214 can be protruded and cured, and the transmission screen can be manufactured more easily and inexpensively.

FIG. 12 is a diagram schematically showing the layer configuration of the solar cell module of Example 3.
The solar cell module 300 includes a solar cell substrate layer 311, a solar cell frame member 312, a back surface protection layer 313, a solar cell adhesive layer 314, and the like, and is a stacked body that generates power using sunlight.
The solar cell substrate layer 311 is a main part of the solar cell module 300 and includes a front glass plate 316, solar cells 317, and the like.
The front glass plate 316 is a glass plate member that serves as a side on which solar light strikes when used as a solar cell and has a role of protecting solar cells.
The solar battery cell 317 is a minimum unit of a solar battery that performs energy conversion that absorbs solar light energy and converts it into electricity, and is arranged on one surface of the front glass plate 316.

The solar cell frame member 312 is an acrylic resin frame that covers the outer peripheral edge of the solar cell substrate layer 311, and the thickness thereof is equal to that of the solar cell substrate layer 311.
The back surface protection layer 313 is a cover layer that protects the back surface of the solar cell substrate layer 311 (the side that is not exposed to sunlight when in use), and covers the solar cell substrate layer 311 and the solar cell frame member 312. The substrate layer 311 and the back surface side of the solar cell frame member 312 are laminated via a solar cell adhesive layer 314.
The solar cell adhesive layer 314 is a layer that adheres the solar cell substrate layer 311, the solar cell frame member 312 and the back surface protective layer 313, and is formed of an epoxy adhesive and has a thickness of 100 μm.
The solar cell adhesive layer 314 is also filled between the solar cell substrate layer 311 and the solar cell frame member 312 and also has a role of bonding them.

The solar cell module 300 in Example 3 can be manufactured by the same manufacturing method as that for the Fresnel lens sheet 110 in Example 1. In the solar cell module 300 in Example 3, the solar cell substrate layer 311 corresponds to the Fresnel substrate layer 111 in Example 1, the solar cell frame member 312 corresponds to the Fresnel frame member 112, and the back surface protective layer 313 has Fresnel. The solar cell adhesive layer 314 corresponds to the lens layer 113, and the Fresnel adhesive layer 114.
According to the present embodiment, since the cutting is performed at the position of the solar cell frame member 312 at the time of manufacture, the solar cell adhesive layer 314 can be protruded and cured, and the solar cell module can be manufactured more easily and inexpensively. Can be provided.

FIG. 13 is a diagram schematically illustrating the layer configuration of the anti-scattering glass of Example 4.
The anti-scattering glass 400 has a glass substrate layer 411, an anti-scattering frame member 412, an anti-scattering layer 413, an anti-scattering adhesive layer 414, etc., and is a highly safe glass that prevents the fragments from scattering when broken. It is the laminated body used.
The glass substrate layer 411 is a main part of the anti-scattering glass 400 and is a general blue plate glass substrate layer.

The scattering prevention frame member 412 is a urethane rubber frame that covers the outer peripheral edge of the glass substrate layer 411, and has a thickness equal to that of the glass substrate layer 411.
The anti-scattering layer 413 is a cover layer that is provided on both surfaces of the glass substrate layer 411 and has a role of preventing the fragments from scattering around even when the glass substrate layer 411 is broken. The film is used.
The scattering prevention layer 413 is laminated on both surfaces of the glass substrate layer 411 and the scattering prevention frame member 412 via the scattering prevention adhesive layer 414 so as to cover both the glass substrate layer 411 and the scattering prevention frame member 412.
The scattering prevention adhesive layer 414 is a layer that adheres the glass substrate layer 411 and the scattering prevention frame member 412 to the scattering prevention layer 413, and is formed of an adhesive material of polyvinyl butyroll.
Note that the anti-scattering adhesive layer 414 is also filled between the glass substrate layer 411 and the anti-scattering frame member 412, and also has a role of bonding them.

The anti-scattering glass 400 in Example 4 can be produced by the same manufacturing method as that for the Fresnel lens sheet 110 in Example 1, although two anti-scattering layers 413 are provided. In the scattering prevention glass 400 in Example 4, the glass substrate layer 411 corresponds to the Fresnel substrate layer 111 in Example 1, the scattering prevention frame member 412 corresponds to the Fresnel frame member 112, and the scattering prevention layer 413 corresponds to the Fresnel lens. The anti-scattering adhesive layer 414 corresponds to the layer 113 and the Fresnel adhesive layer 114.
According to the present embodiment, since the outer peripheral portion of the glass substrate layer 411 is surrounded by the scattering prevention frame member 412, it can be prevented from being damaged by hitting the outer peripheral portion during handling. Further, since the cutting is performed at the position of the anti-scattering frame member 412 at the time of manufacture, the anti-scattering adhesive layer 414 can be protruded and cured, and the anti-scattering glass can be manufactured more easily and can be provided at low cost.

(Modification)
The present invention is not limited to the embodiments described above, and various modifications and changes are possible, and these are also within the equivalent scope of the present invention.
(1) In each Example, although the transmissive screen, the solar cell module, and the scattering prevention glass were mentioned as an example of a laminated body, it was not restricted to this, Other laminated bodies may be sufficient.

(2) In each embodiment, an example in which a glass having translucency is used as a substrate layer is shown. However, the present invention is not limited to this, and for example, it may not have translucency, or glass such as ceramics. Other materials may be used for the substrate layer.

(3) In each of the examples, the Fresnel frame member 112, the lenticular frame member 122, the prism frame member 212, the solar cell frame member 312 and the scattering prevention frame member 412 are examples formed of acrylic resin or urethane rubber. For example, other plastic resins and rubbers such as polycarbonate resin, styrene resin, and butadiene rubber may be used. Moreover, you may use what formed by laminating | stacking two or more types of materials for a frame member as needed.

1 is a cross-sectional view of a rear projection television that uses a transmission screen according to Embodiment 1. FIG. 1 is a perspective view showing a transmission screen of Example 1. FIG. FIG. 3 is a diagram schematically showing a layer configuration of a transmission screen of Example 1. 6 is a cross-sectional view illustrating a method for manufacturing the Fresnel lens sheet 110. FIG. 6 is a cross-sectional view illustrating a method for manufacturing the Fresnel lens sheet 110. FIG. 5 is a perspective view showing a method for manufacturing the Fresnel lens sheet 110. FIG. 5 is a perspective view showing a method for manufacturing the Fresnel lens sheet 110. FIG. FIG. 6 is a cross-sectional view of a rear projection television using the transmission screen of Example 2. 6 is a diagram showing a transmission screen of Example 2. FIG. 6 is a diagram schematically showing a layer configuration of a transmission screen of Example 2. FIG. FIG. 10 is a cross-sectional view illustrating the operation of the prism layer 213. 6 is a diagram schematically showing a layer configuration of a solar cell module of Example 3. FIG. It is the figure which showed typically the layer structure of the scattering prevention glass of Example 4. FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 100 Transmission type screen 110 Fresnel lens sheet 111 Fresnel substrate layer 112 Fresnel frame member 113 Fresnel lens layer 114 Fresnel adhesive layer 120 Lenticular lens sheet 121 Lenticular substrate layer 122 Lenticular frame member 123 Lenticular lens layer 124 Lenticular adhesive layer 125 Front layer 200 Transmission type Screen 211 Prism substrate layer 212 Prism frame member 213 Prism layer 214 Prism adhesive layer 215 Horizontal diffusion layer 216 Non-directional diffusion layer 300 Solar cell module 311 Solar cell substrate layer 312 Solar cell frame member 313 Back surface protection layer 314 Solar cell adhesion layer 400 Anti-scattering glass 411 Glass substrate layer 412 Anti-scattering frame member 413 Anti-scattering layer 414 Anti-scattering adhesive layer

Claims (8)

A method for producing a laminate having a single layer or a substrate layer formed of a plurality of different layers and a cover layer laminated on the substrate layer,
A frame member arranging step of installing a frame member so as to cover the outer peripheral edge of the substrate layer;
An adhesion step of laminating the cover layer via an adhesive layer on at least one surface of the substrate layer and the frame member so as to cover both the substrate layer and the frame member after the frame member arranging step;
After the bonding step, a cutting step of cutting the frame member and the cover layer at a position where the frame member and the cover layer are bonded to each other to have a required external dimension;
The manufacturing method of the laminated body which has this. In the manufacturing method of the laminated body of Claim 1,
The adhesive used for the adhesive layer has fluidity in a state before curing,
The bonding step includes an adhesive pushing step of pushing an unnecessary portion of the adhesive existing between the substrate layer and the frame member and the cover layer to the outer peripheral side of the frame member. Being
The manufacturing method of the laminated body which has this. In the manufacturing method of the laminated body of Claim 1 or Claim 2,
The thickness of the substrate layer in the stacking direction and the thickness of the frame member in the stacking direction are substantially equal;
A method for producing a laminate characterized by the above. In the manufacturing method of the laminated body of any one of Claim 1- Claim 3,
The cover layer is laminated on both sides of the substrate layer and the frame member;
A method for producing a laminate characterized by the above. In the manufacturing method of the laminated body of any one of Claim 1- Claim 4,
The frame member is formed of plastic resin or rubber;
A method for producing a laminate characterized by the above. In the manufacturing method of the laminated body of any one of Claim 1- Claim 5,
In the bonding step, bonding between the substrate layer and the frame member also by the bonding layer,
A method for producing a laminate characterized by the above. In the manufacturing method of the laminated body of any one of Claim 1- Claim 6,
The substrate layer is formed of glass or translucent ceramics;
A method for producing a laminate characterized by the above. In the manufacturing method of the laminated body of Claim 7,
At least a portion of the frame member facing the substrate layer has a light absorption function;
A method for producing a laminate characterized by the above.