JP2007183389A - Method for manufacturing transmission type screen, and rear projection television - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To inexpensively provide a Fresnel lens/prism lens integrated transmission type screen having a high precision pattern, which is obtained by being batch-formed by using an ionizing radiation curable resin. <P>SOLUTION: The method for manufacturing the Fresnel lens 13/prism lens 14 integrated transmission type screen 15 comprises diffusing exposure light by a diffusion plate and irradiating the ionizing radiation curable resin 5 filled at the inside with the exposure light through each opening part 12 between the steric light shielding layers 2 of the prism lens part 3 to cure the resin 5 and to perform butch forming of the Fresnel lens 13 and the prism lens 14. Thus, the high definision transmission type screen is obtained inexpensively. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a transmission screen in an image display device, and more particularly to a molding process that can achieve cost reduction.

  The transmissive screen is composed of a Fresnel lens for making image light emitted from a light source into parallel rays, and a lenticular lens or a prism lens for giving a viewing angle to the image light made parallel by the Fresnel lens. Yes.

  As a publicly known one, a method is generally used in which a Fresnel lens and a lenticular lens are separated from each other, and a lens sheet is joined by a fixing method such as fixing the outer periphery. However, in this method, it is necessary to form each lens sheet separately, and the process becomes complicated.

  As a method for simplifying the molding process and structure, the following method has also been proposed as a method for manufacturing a screen in which a Fresnel lens and a lenticular lens or prism lens are integrated. One is a combination of a Fresnel lens and a prism lens, and is a method of batch molding by injection molding or pressing except for the light shielding layer portion of the prism lens (for example, JP 09-34017 A).

In addition, a method has been proposed in which both front and back lenses (Fresnel lens and prism lens) on a screen are formed of ultraviolet curable resin in separate steps (for example, Japanese Patent Application Laid-Open No. 2004-258071).
JP 09-34017 A JP 2004-258071 A

  However, in the construction method disclosed in Japanese Patent Application Laid-Open No. 09-34017, since a thermoplastic resin is used for lens formation, a fine pitch (specifically, 0.3 mm or less) having a depth due to a heat return phenomenon unique to the thermoplastic resin is used. Although it is difficult to transfer sufficiently, it can be used as a screen for a rear projection television using a CRT, but it is required for a recent MMD (micromirror device) and a high quality rear projection television using a liquid crystal element. A pitch of 0.3 mm or less cannot be achieved, and the screen cannot be used.

  On the other hand, Japanese Patent Application Laid-Open No. 2004-258071 proposes a method of using a photo-curing resin that includes a material that becomes a base material between the front and back lenses. Resin can be used, but the front lens (for example, Fresnel lens) and the back lens (for example, lenticular lens or prism lens) can be molded separately, or the front and back lens can be changed to change the material. The structure and process are complicated, such as the necessity to form.

  The present invention is for solving the above-described problems, and enables a Fresnel lens and a prism lens to be integrally formed, and a high-quality transmissive screen is manufactured at a low cost by simplifying the manufacturing process and structure. For the purpose.

  In order to solve the above-described conventional problems, the transmissive screen manufacturing method of the present invention includes a three-dimensional light shielding layer having an isosceles triangular cross section for diffusing and transmitting light rays incident from a projection lens to the exit surface side. In a method for manufacturing a transmission screen having a prism lens and a Fresnel lens, a step of installing a diffusion plate on the other surface of the transparent substrate of the three-dimensional light shielding layer sheet on which the three-dimensional light shielding layer is formed on the transparent substrate, and projecting An installation step of installing a Fresnel lens mold that forms a Fresnel lens by forming a space filled with an ionizing radiation curable resin between the three-dimensional shading layer sheet and disposed on the incident side of the image light beam; and the formed space Filling with an ionizing radiation curable resin, and in order to cure the ionizing radiation curable resin, a light beam from an exposure light source is passed through the diffusion plate and the three-dimensional light shielding layer It is obtained characterized by means curing the ionizing radiation curable resin by irradiation through the opening.

  In addition, the transmissive screen manufacturing method of the present invention includes a prism lens and a Fresnel lens that are configured by a three-dimensional light shielding layer having an isosceles triangle in cross section for diffusing and transmitting a light beam incident from a projection lens to the exit surface side. In the transmissive screen manufacturing method, the step of placing the three-dimensional light-shielding layer sheet having the three-dimensional light-shielding layer formed on the diffusion plate on the glass substrate; the three-dimensional light-shielding layer sheet disposed on the incident side of the projected image light beam; An installation step of installing a Fresnel lens mold that forms a Fresnel lens by forming a space filled with an ionizing ray curable resin, and a filling step of filling the formed space with an ionizing ray curable resin, In order to cure the ionizing radiation curable resin, the ionization light source is irradiated with light from an exposure light source through the glass plate and through the opening between the three-dimensional light shielding layers. It is obtained characterized by means curing the curable resin.

  In addition, the transmissive screen manufacturing method of the present invention includes a prism lens and a Fresnel lens that are configured by a three-dimensional light shielding layer having an isosceles triangle in cross section for diffusing and transmitting a light beam incident from a projection lens to the exit surface side. In the transmissive screen manufacturing method, a step of placing a three-dimensional light shielding layer sheet on which a three-dimensional light shielding layer is formed on a transparent substrate on a glass substrate, and a three-dimensional light shielding layer sheet disposed on an incident side of a projected image light beam, An installation step of forming a Fresnel lens mold in which a mold surface for forming a Fresnel lens is formed by forming a space for filling the ionizing radiation curable resin between the mirror surface and filling the formed space with the ionizing radiation curable resin. And a filling step for irradiating light from an exposure light source through the glass plate and through the opening between the three-dimensional light shielding layers in order to cure the ionizing radiation curable resin. And is obtained by, characterized in that is reflected by the mirror-finished portion of the Fresnel lens refers curing the ionizing radiation curable resin.

  The rear projection television of the present invention is a rear projection television using a transmissive screen manufactured by the method according to any one of claims 1, 2, and 4.

  FIG. 11A shows the configuration of the transmissive screen 15 obtained by the transmissive screen manufacturing method of the present invention. In the transmission screen 15 obtained by the manufacturing method of the present invention, a Fresnel lens 13 for converting image light into parallel rays on the image light incident side and a prism lens 14 for diffusing the image light that has become parallel rays are integrated. Formed. The prism lens 14 is formed by a three-dimensional light-shielding layer 2 whose cross-sectional shape is an isosceles triangle for suppressing light incident from the outgoing light side to the incident light side, and is formed of the three-dimensional light-shielding layer 2 shown in FIG. The image light is diffused by using the reflection on the side wall surface 17 to improve the viewing angle with respect to the observer. In FIG. 11A, the optical path 11 of the image light emitted from the image light source 21 and incident from the Fresnel lens 13 side and emitted from the prism lens 14 is shown.

  An example in which the transmissive screen 15 obtained by the present invention is used in the rear projection television 17 will be described with reference to a cross-sectional view shown in FIG. The rear projection television 17 forms an image on the transmission screen 15 of the present invention by using the mirror 19 and the projection lens 20 with the video light emitted from the projector 18 inside the television. The transmission type screen 15 of the present invention includes a Fresnel lens 13 for making image light parallel rays on the image light incident side, and a prism lens 14 for diffusing the image light that has become parallel rays to improve the viewing angle. It is integrally formed. In order to further diffuse the image light diffused by the prism lens 14, the diffusion plate 9 is used outside the prism lens 14 to diffuse the light in the entire peripheral direction. In this way, the screen 15 and the diffusing plate 9 have a diffusion effect, so that the viewing angle of the image light is given, and the luminance change is less likely to occur even if the observer's viewing position is different. In the figure, the optical path 11 of the image light emitted from the projector 18 is shown.

  A first embodiment of the present invention will be described with reference to FIGS.

  FIG. 7A shows a cross-sectional view of the three-dimensional light shielding layer sheet 3 used in Example 1. FIG. The three-dimensional light shielding layer sheet 3 used in Example 1 is obtained by forming the three-dimensional light shielding layer 2 whose cross-sectional shape is an isosceles triangle on the transparent substrate 1. As a molding method of the three-dimensional light shielding layer 2, it can be formed by mold transfer. The three-dimensional light shielding layer 2 can be formed of a resin in which a pigment is dispersed. For example, a material in which a black pigment is dispersed in a urethane resin or an epoxy resin can be used. On the other hand, as the transparent substrate 1, polymethyl methacrylate (PMMA), methacryl styrene (MS) polycarbonate (PC), cycloolefin polymer (COP), polyethylene terephthalate (PET) or the like can be used.

  Further, in order to obtain total reflection at the side wall surface 17 of the three-dimensional light shielding layer 2 shown in FIG. 7B, the refractive index of the three-dimensional light shielding layer 2 is changed to the three-dimensional light shielding layer forming sheet 3 and the Fresnel lens shown in the subsequent step 3. A taper angle of the three-dimensional light shielding layer 2 that can obtain total reflection is determined according to Snell's law, using a refractive index material lower than the refractive index of the ionizing radiation curable resin 5 that is a lens forming material filled between the molds 4.

  FIG. 10 shows a cross-sectional view of the Fresnel lens type used in Example 1. As the Fresnel lens type used in the first embodiment, a refractive type and a reflective type Fresnel lens type are set according to an incident angle of incident light depending on an arrangement of a light source to be projected when actually used. Is not limited. The entire surface of the Fresnel lens mold 4 is provided with a surface treatment layer 6 such as coating with a fluorine-based resin in order to improve mold separation after curing the ionizing radiation curable resin.

  1 and 2 show a cross section of the main part in the molding process of the screen 15 of the present invention.

  Below, the formation process of the screen 15 is demonstrated using FIG. 1, FIG.

  FIG. 1A shows an installation process of the three-dimensional light shielding layer sheet 3 as the process 1. The three-dimensional light shielding layer sheet 3 is installed on a glass plate 8, and a diffusion plate 9 for diffusing exposure light rays is installed below the glass plate 8. Further, an exposure light source 10 is installed below the diffusion plate 9.

  FIG. 1B shows an installation process of the Fresnel lens mold 4 as the process 2. The Fresnel lens mold 4 is installed on the upper part of the three-dimensional light shielding layer sheet 3 in the state of FIG. 1A to form a filling space 7 filled with an ionizing ray curable resin that forms a Fresnel lens and a prism lens.

  FIG. 1C shows a filling process of the ionizing radiation curable resin 5 as the process 3. The ionizing radiation curable resin 5 is injected into the filling space 7 shown in FIG. 1B by using a non-illustrated injection port and discharge port by vacuum injection, pressure injection, or the like. Here, the ionizing radiation curable resin 5 may be, for example, a general ultraviolet curable resin, and one having a refractive index higher than that of the three-dimensional light shielding layer 2 forming member is used.

  FIG. 2 shows a step of curing the ionizing radiation curable resin as step 4. The light beam emitted from the exposure light source 10 is diffused by the diffusion plate 9 as shown by the optical path 11 of the exposure light beam in the drawing, passes through the glass plate 8, and is formed on the three-dimensional light shielding layer sheet 3. It enters into the ionizing radiation curable resin portion from the opening 12 therebetween, and the ionizing radiation curable resin 5 is cured. The diffusion plate 9 may be anything as long as it has an effect of diffusing light, but one having a diffusion effect larger than the taper angle of the three-dimensional light shielding layer 2 is used. Further, various lenses or lenses that promote diffraction of light rays may be used. Here, the position of the diffusion plate 9 is placed below the glass plate 8, but it may be anywhere between the three-dimensional light shielding layer sheet 3 and the exposure light source 10, and between the glass plate 8 and the three-dimensional light shielding layer sheet 2. May be.

  By the above method, the Fresnel lens 13 and prism lens 14 integrated screen 15 shown in FIG. 11 is formed.

  The advantage of the present invention in the first embodiment is that the ionizing radiation curable resin 5 is exposed and cured, and the Fresnel lens 13 and the prism lens 14 are integrally molded together, thereby simplifying the manufacturing process and structure, and achieving high quality at a low price. It is possible to manufacture a transparent screen. In the present invention, the three-dimensional light shielding layer sheet 3 is installed on the glass plate 8, and the diffusion plate 9 for diffusing the exposure light beam is installed below the glass plate 8. Therefore, the rear projection television shown in FIG. For example, the transmission screen can be formed without depending on the surface state, material, and shape of the diffusion plate 9.

  A second embodiment of the present invention will be described with reference to FIGS.

  FIG. 8A shows a cross-sectional view of the three-dimensional light shielding layer sheet 203. The three-dimensional light shielding layer sheet 203 used in Example 2 is obtained by forming the three-dimensional light shielding layer 2 whose cross-sectional shape is an isosceles triangle on the diffusion substrate 209. As a molding method of the three-dimensional light shielding layer 2, it can be formed by mold transfer. Here, as the diffusion substrate 209, for example, a resin substrate in which glass beads having a refractive index different from that of the resin are dispersed is used.

  Further, in order to obtain total reflection at the side wall surface 17 of the three-dimensional light shielding layer 203 shown in FIG. 8B, the refractive index of the three-dimensional light shielding layer 2 is changed to the three-dimensional light shielding layer forming sheet 3 and the Fresnel lens shown in the subsequent step 3. A taper angle of the three-dimensional light shielding layer 2 that can obtain total reflection is determined according to Snell's law, using a refractive index material lower than the refractive index of the ionizing radiation curable resin 5 that is a lens forming material filled between the molds 4.

  The Fresnel lens mold used in the second embodiment may be the same as the Fresnel lens mold shown in FIG.

  3 and 4 show a cross section of the main part in the molding process of the screen 15 of the present invention shown in FIG.

  Hereinafter, the molding process of the screen 15 will be described with reference to FIG.

  FIG. 3A shows an installation process of the three-dimensional light shielding layer sheet 203 as the process 1. The three-dimensional light shielding layer sheet 203 is installed on the glass plate 8, and the exposure light source 10 is installed below the glass plate 8.

  FIG. 3B shows an installation process of the Fresnel lens mold 4 as the process 2. The Fresnel lens mold 4 is installed on the upper part of the three-dimensional light shielding layer sheet 203 in the state of FIG. 3A to form a filling space 7 filled with an ionizing ray curable resin that forms a Fresnel lens and a prism lens.

  FIG. 3C shows a filling step of the ionizing radiation curable resin 5 as step 3. The ionizing radiation curable resin 5 is injected into the filling space 7 shown in FIG. 3 (b) by using a non-illustrated inlet and outlet by vacuum injection, pressure injection, or the like. Here, the ionizing radiation curable resin 5 may be, for example, a general ultraviolet curable resin, and one having a refractive index higher than that of the three-dimensional light shielding layer 2 forming member is used.

  FIG. 4 shows a step of curing the ionizing radiation curable resin as step 4. The light beam emitted from the exposure light source 10 is transmitted through the glass plate 8 and diffused by the diffusion substrate 209 as shown by the optical path 11 of the exposure light beam in the drawing, and is formed on the three-dimensional light shielding layer sheet 203. It enters into the ionizing radiation curable resin portion from the opening 12 therebetween, and the ionizing radiation curable resin 5 is cured. The diffusion substrate 209 may be anything as long as it is a flat substrate having an effect of diffusing light, but a substrate having a diffusion effect larger than the taper angle of the three-dimensional light shielding layer 2 is used.

  By the above method, the Fresnel lens 13 and prism lens 14 integrated screen 15 shown in FIG. 11 is formed.

  Advantages of the present invention in the second embodiment are that the ionizing radiation curable resin 5 is exposed and cured to integrally form the Fresnel lens 13 and the prism lens 14 together, and the solid light shielding layer 2 is directly formed on the diffusion substrate 209. By simplifying the manufacturing process and structure, it is possible to manufacture a low-priced and high-quality transmissive screen.

  A third embodiment of the present invention will be described with reference to FIGS.

  FIG. 9 shows a cross-sectional view of the Fresnel lens mold 304. The surface of the Fresnel lens mold 304 is subjected to surface treatment to form the specular reflection layer 16. One method of surface treatment is PVD chromium nitride (CrN) which has releasability and can obtain specular reflection. Further, the base material itself of the Fresnel lens mold 4 may be made of a metal so that specular reflection is obtained, and the surface thereof may be coated with a transparent coating layer to have a releasability.

  As the three-dimensional light shielding layer sheet 3 used in Example 3, the three-dimensional light shielding layer sheet 3 shown in FIG. 7 used in Example 1 and the three-dimensional light shielding layer sheets 3 and 203 shown in FIG. 8 used in Example 2 can be used. .

  5 and 6 show a cross section of the main part in the molding process of the screen 15 of the present invention shown in FIG.

  Below, the formation process of the screen 15 is demonstrated using FIG. 5, FIG.

  FIG. 5A shows an installation process of the three-dimensional light shielding layer sheet 3 as the process 1. The three-dimensional light shielding layer sheet 3 is installed on a glass plate 8, and an exposure light source 10 is installed below the glass plate 8.

  FIG. 5B shows an installation step of the Fresnel lens mold 304 as step 2. The Fresnel lens mold 304 is installed on the upper part of the three-dimensional light shielding layer sheet 3 in the state of FIG. 3A to form a filling space 7 filled with an ionizing ray curable resin that forms a Fresnel lens and a prism lens.

  As Step 3 of Example 3, FIG. 5C shows a filling step of the ionizing radiation curable resin 5. The ionizing radiation curable resin 5 is injected into the filling space 7 shown in FIG. 5B by using a non-illustrated injection port and discharge port by vacuum injection, pressure injection, or the like. Here, the ionizing radiation curable resin 5 may be, for example, a general ultraviolet curable resin, and one having a refractive index higher than that of the three-dimensional light shielding layer 2 forming member is used.

  FIG. 6 shows a step of curing the ionizing radiation curable resin as step 4. Light rays emitted from the exposure light source 10 are transmitted through the glass plate 8 as shown by an optical path 11 of the exposure light beam in the drawing, and are ionized through the opening 12 between the three-dimensional light shielding layers 2 formed on the three-dimensional light shielding layer sheet 203. Resin 5 is irradiated and cured. Furthermore, the exposure light beam undergoes complex reflection in the filling space 7 of the ionizing ray curable resin, with primary reflection at the specular reflection layer 16 on the surface of the Fresnel lens mold 304 and secondary reflection at the side wall surface of the solid light shielding layer 2. The ionizing radiation curable resin 5 is cured.

  By the above method, the Fresnel lens 13 and prism lens 14 integrated screen 15 shown in FIG. 11 is formed.

  Thus, although the Example in this invention is shown, Furthermore, the combination of Example 1 and Example 3, the combination of Example 2 and Example 3, etc. can be considered. The advantage of the present invention in Example 3 is that the ionizing radiation curable resin 5 is exposed and cured to simplify the manufacturing process and structure by integrally molding the Fresnel lens 13 and the prism lens 14 at a low cost, and high quality. It is possible to manufacture a transparent screen.

  By using the above construction method, it is possible to provide a Fresnel lens and prism lens integrated transmission screen with ionizing radiation curable resin with a simplified structure and process, and to provide a high-definition and inexpensive transmission screen. To do.

  The transmissive screen of the present invention is advantageous in reducing the cost of an MD (microdevice) projection television screen using a DMD or a liquid crystal element.

The figure which shows the process of the manufacturing method of the transmission type screen in Example 1 of this invention. The figure which shows the exposure process of the manufacturing method of the transmission type screen in Example 1 of this invention. The figure which shows the process of the manufacturing method of the transmission type screen in Example 2 of this invention. The figure which shows the exposure process of the manufacturing method of the transmission type screen in Example 2 of this invention. The figure which shows the process of the manufacturing method of the transmission type screen in Example 3 of this invention. The figure which shows the exposure process of the manufacturing method of the transmission type screen in Example 3 of this invention. The figure which shows the solid light shielding layer sheet used for Example 1 The figure which shows the solid light shielding layer sheet used for Example 2 The figure which shows the Fresnel lens type | mold which has a surface reflection layer used for Example 3 The figure which shows the Fresnel lens type | mold which performed the surface treatment used for Example 1 and Example 2. The figure which shows the screen of the Fresnel lens and prism lens integrated type which used the manufacturing method of the transmission type screen of this invention. The figure which shows typically the rear projection television using the transmissive screen manufactured using the manufacturing method of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Transparent substrate 2 203 Three-dimensional light shielding layer 3 Three-dimensional light shielding layer sheet 4 304 Fresnel lens type | mold 5 Ionization ray hardening resin 6 Surface treatment 7 Filling space 8 Glass plate 9 209 Diffusing plate 10 Exposure light source 11 Optical path 12 Opening part 13 Fresnel lens 14 Prism lens 15 screen 16 specular reflection layer

Claims (5)

In a method of manufacturing a transmission type screen having a prism lens composed of a three-dimensional light-shielding layer having an isosceles triangle cross section for diffusing and transmitting light rays incident from a projection lens to the exit surface side,
Installing a diffusion plate on the other surface of the transparent substrate of the three-dimensional light-shielding layer sheet in which the three-dimensional light-shielding layer is formed on the transparent substrate;
An installation step of installing a Fresnel lens mold that is disposed on the incident side of the image light to be projected and forms a Fresnel lens by forming a space filled with ionizing radiation curable resin between the three-dimensional light shielding layer sheet;
A filling step of filling the formed space with an ionizing radiation curable resin;
With
In order to cure the ionizing radiation curable resin, the ionizing radiation curable resin is cured by irradiating light from an exposure light source through the diffusion plate and through the opening between the three-dimensional light shielding layers. Screen manufacturing method. In a method of manufacturing a transmission screen having a prism lens and a Fresnel lens, each of which has a cross-section of an isosceles triangular cross section that diffuses and transmits light incident from a projection lens to the exit surface side.
Installing a three-dimensional light shielding layer sheet having the three-dimensional light shielding layer formed on a diffusion plate on a glass substrate;
An installation step of installing a Fresnel lens mold that is disposed on the incident side of the image light to be projected and forms a Fresnel lens by forming a space filled with ionizing radiation curable resin between the three-dimensional light shielding layer sheet;
A filling step of filling the formed space with an ionizing radiation curable resin;
With
In order to cure the ionizing radiation curable resin, the ionizing radiation curable resin is cured by irradiating a light beam from an exposure light source through the glass plate and through an opening between the three-dimensional light shielding layers. Screen manufacturing method. 3. The method of manufacturing a projection type screen according to claim 1, wherein the entire surface of the Fresnel lens is surface-treated with a fluorine resin coating. In a method of manufacturing a transmission screen having a prism lens and a Fresnel lens, each of which has a cross-section of an isosceles triangular cross section that diffuses and transmits light incident from a projection lens to the exit surface side.
Installing a three-dimensional light shielding layer sheet having the three-dimensional light shielding layer formed on a transparent substrate on a glass substrate;
A Fresnel lens mold, which is disposed on the incident side of the projected image light beam and forms a Fresnel lens by forming a space filled with an ionizing radiation curable resin between the three-dimensional light shielding layer sheet and a mirror-finished mold surface is installed. Installation process;
A filling step of filling the formed space with an ionizing radiation curable resin;
With
In order to cure the ionizing radiation curable resin, the ionizing radiation curable resin is irradiated with light from an exposure light source through the glass plate and through an opening between the three-dimensional light shielding layers, and reflected by a mirror surface processing portion of the Fresnel lens. A method for producing a transmission type screen, characterized by curing. A rear projection television using a transmissive screen manufactured by the method according to claim 1, claim 2, or claim 4.

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