JP2007264184A - Transmission type rear screen and manufacturing method therefor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a transmission type rear screen as an optical component for a rear projection type television, which has a lenticular lens array face and projections formed on parts other than the condensing parts of the condensing face opposite to the lenticular lens array face and to provide a manufacturing method for the transmission type rear screen, the transmission type rear screen being designed so that the dimension stability of lens pitches is stable in the manufacture of the screen, the lenticular lens array as the transmission type rear screen and the projections on the condensing face opposite to the lens array are easily aligned and the formation of a light shield layer is also easy. <P>SOLUTION: A lenticular lens array layer 2 is formed on one side of a base material film layer 1. The projections 3 of a predetermined width are formed on the other side of the base film layer 1 and on parts other than the condensing parts of the lenticular lens array layer 2. The light shield layer 4 is formed on the top face of each projection 3. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a transmissive rear screen such as a projection screen of a projector-enlarged rear projection television and a method for manufacturing the same.

  Conventionally, a rear projection television (rear projection TV) has mainly been required to have brightness of a screen and a wide viewing angle.

  The transmissive rear screen used in rear projection televisions has optical characteristics such as wide viewing angle, high contrast, low glare, no moire, no stray light, blur, and distortion. Is required.

  If the viewing angle is wide, the visible area of the image is widened for the observer, and if the contrast is high, the visibility of the image is high, and if the glare is small, the observer's eyes are less fatigued, moire, and stray light. If there is no blur or distortion, the video quality will be improved.

  In particular, as one of means for expanding the viewing angle, there is a method of using a lenticular lens sheet in which cylindrical lens groups are arranged in parallel and expanding projected image light in a horizontal direction or a vertical direction with respect to the screen.

  Furthermore, a method of isotropically expanding the image light by providing a light diffusing material or the like in any layer constituting the screen, such as a substrate or a lens, is adopted.

Further, by providing an appropriate light-shielding layer on the lenticular lens sheet, it is possible to absorb external light reflection and stray light (multiple reflected light in the screen) and improve contrast. A self-alignment method is known as a method of providing a light-shielding layer that does not reduce the efficiency of image light incident on a lens. (For example, see Patent Documents 1 and 2)
The known literature relating to the present invention is described below.
JP-A-9-120101 By the way, a lenticular lens sheet of a transmissive rear screen as an optical component for a rear projection type television includes a lenticular lens sheet having a flat condensing surface side opposite to the lenticular lens array surface, There is a lenticular lens sheet having a convex portion in a portion other than the light collecting portion on the light collecting surface side.

  As a method of providing a light shielding layer on the light condensing surface side of such a lenticular lens sheet, the self-alignment method is an appropriate method when the light condensing surface side of the lenticular lens sheet is a flat surface. When a convex portion is provided in a portion other than the light portion, the self-alignment method is not suitable because of the uneven surface.

The present invention relates to a transmissive rear screen as an optical component for a rear projection television having a convex portion in a portion other than the light condensing portion on the condensing surface side opposite to the lenticular lens array surface, and a method for manufacturing the same. Thus, the dimensional stability of the lens pitch in the screen manufacturing is good, and the alignment of the lenticular lens array as a transmissive rear screen and the convex portion on the condensing surface side opposite to the lens array and the formation of a light shielding layer are possible. An object is to provide an easy transmission rear screen and a method of manufacturing the same.

  The invention according to claim 1 of the present invention includes a lenticular lens array layer 2 on one surface of the base film layer 1, and other than the condensing part of the lenticular lens array layer 2 on the other surface of the base film layer 1. The transmissive rear screen is characterized in that a convex portion 3 having a predetermined width is provided in a portion, and a light shielding layer 4 is provided on the top surface of the convex portion 3.

  The invention according to claim 2 of the present invention includes a first resin application step of applying an ultraviolet curable resin to one surface of the substrate film layer 1, and an ultraviolet curable resin layer 2 applied to the substrate film layer 1. Is introduced between a roll mold for forming a lenticular lens array and a pressure roll and pressurized, and an ultraviolet curable resin layer 2 is provided between the base film layer 1 and the roll mold. An ultraviolet irradiation curing process in which the resin layer 2 is cured by irradiating ultraviolet rays while being sandwiched, and the resin layer 2 cured as the base film layer 1 and the lenticular lens array layer 2 is removed from a roll mold for forming a lenticular lens array. A resin peeling step for peeling, a second resin coating step for applying an ultraviolet curable resin to the other surface of the peeled base film layer 1, and an ultraviolet curable resin layer 3 applied to the base film layer 1 Convex A second resin introduction pressurizing step for introducing and pressurizing between the part forming roll mold and the pressure roll, and an ultraviolet curable resin layer 3 between the base film layer 1 and the roll mold. A second ultraviolet irradiation curing step of curing the resin layer 3 by irradiating the ultraviolet ray while being sandwiched, and a roll gold for forming the convex portion as the base film layer 1 and the convex portion 3 A transmission type comprising: a second resin peeling step for peeling from the mold; and a light shielding layer forming step for forming a light shielding layer 4 by applying a light shielding ink to the top surface cured as the convex portion 3 It is a manufacturing method of a rear screen.

  According to the transmissive rear screen and the transmissive rear screen manufacturing method of the present invention, a rear projection type provided with a convex portion in a portion other than the lenticular lens array surface and the condensing portion on the condensing surface side on the opposite surface. A transmissive rear screen as an optical component for television and a method of manufacturing the transmissive rear screen, which has good dimensional stability of the lens pitch in manufacturing the screen, and a lenticular lens array as the transmissive rear screen, and a surface opposite to the lens array Therefore, it is possible to provide a transmission type rear screen that is accurately positioned and formed with the convex portion on the light converging surface side, and that makes it very easy to form a light shielding layer, and a method for manufacturing the same.

  The transmission type rear screen of the present invention will be described in detail below based on the side cross section of FIG.

  As shown in FIG. 1, the transmissive rear screen A of the present invention includes a lenticular lens array layer 2 in which a large number of minute cylindrical lenses (saddle-shaped lenses) having the same pitch p are arranged on one surface of a base film layer 1. I have.

  Video light L enlarged and projected from a magnifying optical system of a television projector and converted into parallel light by a Fresnel lens sheet (not shown) is incident on the lenticular lens array layer 2 and is each made of a base film by a cylindrical lens. It concentrates on each condensing part 1a, 1a, 1a, ... of the other surface side of the layer 1, and radiate | emits from the other surface side of the base film layer 1. FIG. The optical path of the video light L emitted from the base film layer 1 is an optical path when the base film layer 1 is a transparent film and the diffusion function by the base film layer 1 is not considered.

  Since each cylindrical lens of the lenticular lens array layer 2 is set so that its focal point exists inside or outside the base film layer 1, an image of parallel light incident on the lenticular lens array layer 2 is obtained. As shown in the drawing, the light L is incident on each of the light condensing portions 1a, 1a, 1a,... On the other surface of the base film layer 1 that is opposite to the lenticular lens array layer 2 or on the lenticular lens array layer. 2 and the base film layer 1, or each of the light condensing portions 1 a, 1 a, 1 a,... In the base film layer 1 is condensed with a predetermined width t. .

  Each portion of the base film layer 1 other than the light collecting portions 1a, 1a, 1a,... Is provided with a convex portion 3 having a predetermined height h and a predetermined width s1. The portion is the light condensing part 1a which is a non-light-shielding part having a predetermined width s2, and a dark-colored light-shielding layer 4 (for example, a black stripe) is provided on the entire top surface of each convex part 3. . It is appropriate that the light collection width t of the image light L with respect to the width s2 of the light collecting portion (non-light-shielding portion) 1a is t ≦ s2.

  The base film layer 1 in the present invention may be a transparent film or a transparent sheet that does not have light diffusibility at all, or may be a light diffusible film or sheet that has light diffusibility.

  As the base film layer 1, for example, a light diffusibility mixed with a light diffusing agent such as fine powder or bead powder (organic bead) made of glass or plastic, or a powdered light diffusing agent such as calcium carbonate or kaolin. It may be a film or a light diffusing sheet (diffusion sheet). Or what provided the fine unevenness | corrugation in the single side | surface (light emission side) of the said base film layer 1 by the transparent film of a single layer, and gave light diffusibility. Alternatively, the base film layer 1 may be a laminated film of a transparent film (light incident side) and a light diffusing film (light emitting side).

  2 is a plan view of the transmissive rear screen A of the present invention as viewed from above the lenticular lens array layer 2. FIG. 3 is a plan view of the transmissive rear screen A of the present invention as viewed from above the convex portion 3 and the light shielding layer 4. It is a plan view, and shows a case where cutting is performed on a cutting line C and divided into, for example, three sheets.

  In the transmissive rear screen A of the present invention, as shown in FIG. 1, the parallel image light L incident on the lenticular lens array layer 2 is opposite to the lenticular lens array layer 2. , Or the boundary between the lenticular lens array layer 2 and the base film layer 1, which is the base film layer 1 side on the lenticular lens array layer 2 side, on each of the light condensing portions 1a, 1a, 1a,. .. Are condensed with a predetermined width t on each of the condensing portions 1a, 1a, 1a,...

  When the base film layer 1 is a transparent film or sheet having no light diffusibility, as shown in FIG. 1, the video light L condensed by the lenticular lens array layer 2 with a predetermined width t is the base film. Through the transparent film as the layer 1, the light is diffused in a predetermined direction corresponding to the optical path condensed by the lenticular lens array layer 2, and the light shielding layer 4 side (Fresnel lens) of the transmission type rear screen A of the present invention. It is delivered as diffused image light diffused to a predetermined viewing angle to an observer on the side opposite to the sheet.

When the base film layer 1 is a light diffusive film or sheet, the video light L condensed with a predetermined width t by the lenticular lens array layer 2 is the base film layer 1. Or the sheet is diffused in a predetermined direction corresponding to the light path condensed by the lenticular lens array layer 2 and the light diffusion light path by the base film layer 1, and the transmission type rear screen A of the present invention. This is delivered as diffused image light diffused to a predetermined viewing angle to an observer on the light shielding layer 4 side (opposite side to the Fresnel lens sheet).

  Next, an embodiment of the transmissive rear screen manufacturing method of the present invention will be described below based on the side view of the transmissive rear screen manufacturing apparatus in FIG. 4 and the transmissive rear screen manufacturing process in FIGS. This will be described in detail.

  As shown in FIG. 4, in the first resin coating process, while the base film layer 1 is fed with a take-up roll sheet-like or sheet-like resin film (hereinafter referred to as the base film layer 1) Then, an ultraviolet curable resin is applied to one surface of the resin film using the application means 11 (application roll 11, resin supply roll 11a, resin supply tank 11b).

  Subsequently, in the resin introduction pressurization step, the base film layer 1 is guided by the guide roll g, and the applied UV curable resin layer 2 and the lenticular lens array forming roll mold 12 and the pressure roll 13 are used. And pressurize between.

  Subsequently, in the ultraviolet irradiation curing step, the base film layer 1 and the ultraviolet curable resin layer 2 are passed between the lenticular lens array forming roll mold 12 and the pressure roll 13, and the ultraviolet curable mold is passed. While sandwiching (holding) the resin layer 2 between the base film layer 1 and the roll mold 12 for forming the lenticular lens array, the UV irradiation means 14 irradiates the base film layer 1 side with ultraviolet rays, The resin layer 2 is cured as the lenticular lens array layer 2. In addition, although it does not specifically limit as resin used for the base film layer 1 and the ultraviolet curable resin layer 2, For example, a polyethylene terephthalate, a polymethylmethacrylate, a styrene etc. are mentioned. In addition, examples of the ultraviolet curable resin include polyester-based, acrylic-based, and styrene-based ultraviolet curable resins.

  Subsequently, in the resin peeling step, the base film layer 1 and the resin layer 2 cured as a lenticular lens array are peeled from the roll mold 12 for forming a lenticular lens array via a peeling roll 15. Thereby, as shown in FIGS. 2 and 5, a laminated molded body in which the lenticular lens array layer 2 is laminated on one surface of the base film layer 1 is obtained. In FIG. 2, X is the supply / feed direction of the base film layer 1.

  Subsequently, in the second resin coating step, coating means 16 (coating roll 16, resin supply roll 16a, resin supply tank 16b) is used on the other surface of the base film layer 1 peeled as shown in FIG. Then, apply UV curable resin.

  Subsequently, in the second resin introduction pressure step, the base film layer 1 and the applied ultraviolet curable resin layer 3 are introduced between the convex portion forming roll mold 17 and the pressure roll 18. Pressurize. In this case, the convex part forming die of the convex part forming roll mold 17 is positioned at a portion other than the light condensing part 1a of the lenticular lens array layer 2 formed in the resin introduction pressurizing step. Further, the position of the convex portion forming roll mold 17 in the rotational axis direction is adjusted and set with respect to the position of the lens array forming roll mold 12 in the rotational axis direction.

  Subsequently, in the second ultraviolet irradiation curing step, the base film layer 1, the lenticular lens array layer 2, and the ultraviolet curable resin layer 3 are bonded to the convex portion forming roll mold 17 and the pressure roll 18. The ultraviolet curable resin layer 3 is sandwiched (held) between the base film layer 1 and the convex portion forming roll mold 17 while passing through the base film layer 1 by the ultraviolet irradiation means 19. The resin layer 3 is cured as the convex portion 3 by irradiating ultraviolet rays from the (lenticular lens array layer 2) side. The ultraviolet curable resin layer 3 is not particularly limited in the present invention, and examples thereof include ultraviolet curable resins such as polyester, acrylic, and styrene.

  Subsequently, in the second resin peeling step, the base film layer 1 and the lenticular lens array layer 2 together with the resin layer 3 cured as the convex part 3 are transferred to the convex part forming roll via the peeling roll 20. Peel from the mold 17. Thereby, as shown in FIG. 6, the lenticular lens array layer 2 is laminated on one surface of the base film layer 1, and the convex portion 3 is laminated on the other surface (the portion other than the condensing portion 1a of the lens array layer 2). A molded body is obtained.

  Subsequently, in the light shielding layer forming step, the base film layer 1 in which the lenticular lens array layer 2 is laminated on one surface and the convex portion 3 is laminated on the other surface is applied to the coating means 21 (coating roll 21, light shielding colored ink paint). Introducing between the supply roll 21a and the ink paint supply tank 121) and the pressure roll 22, and rolling the application roll 21 to which the light-shielding ink and paint are attached on the top surface of the convex portion 3, the dark and dark A light-shielding ink or paint having a color tone (for example, black) is applied to form the light-shielding layer 4 on the top surface of the convex portion 3. Thus, as shown in FIGS. 3 and 7, the lenticular lens array layer 2 is formed on one surface of the base film layer 1, the striped convex portion 3 is formed on the other surface, and the light shielding layer 4 is formed on the top surface of the convex portion 3. Thus, the transmission type rear screen of the present invention in which is laminated is obtained. In FIG. 3, X is the supply / feed direction of the base film layer 1.

  The above is the manufacturing method of the transmission type rear screen of the present invention. In the manufacturing process, the lenticular lens array layer 2 and the convex portion 3 are laminated and formed on one side and the other side of the base film layer 1 respectively. In the forming position alignment, an appropriate alignment mark (registering mark) can be applied.

  FIG. 8 is a side view of the lenticular lens array molding roll mold 12 used in the manufacturing process, and FIG. 9 is a side view of the convex part forming roll mold 17 used in the manufacturing process. is there.

  As shown in FIG. 8, a lenticular lens array mold 12b is cut into a spiral shape or a ring shape along the peripheral surface of the roll peripheral surface of the lenticular lens array molding roll mold 12. An appropriate shape (for example, a cross-shaped mark, a circular shape, etc.) is provided in each of the uncut peripheral margin portions of the array molding die portion 12b at both ends of the roll die 12 in the direction of the rotation support shaft 12a. A convex or concave alignment mark mold 12c is formed.

  Further, as shown in FIG. 9, the convex portion molding die portion 17 b is cut into a spiral shape or a ring shape along the peripheral surface of the roll peripheral surface of the convex portion forming roll die 17. In each one of the uncut peripheral portions of the array molding die 17b at both ends of the roll die 17 in the direction of the rotation support shaft 17a, an appropriate shape (for example, a cross mark) , A circular mark, a triangular mark, or the like) or a concave alignment mark mold part 17c (which may be colored so as to be visible through the base film 1) is formed.

  FIG. 10 is supplied and sent in the X direction in the manufacturing process shown in FIG. 4 using the lenticular lens array molding roll mold 12 shown in FIG. 8 and the convex part molding roll mold 17 shown in FIG. This is a transmission type rear screen A of the present invention in which a base film layer 1 and a lenticular lens array layer 2 and a convex portion 3 are laminated and formed.

As shown in FIG. 4, in the first resin introduction pressurizing step and the first ultraviolet irradiation curing step, the ultraviolet curable resin layer 2 applied to one surface of the base film layer 1 is used as a lenticular lens array molding roll metal. By curing the ultraviolet curable resin layer 2 as a lenticular lens array layer 2 while being molded by irradiation with the mold 12 and the ultraviolet irradiation means 14, the lens array layer 2 of the transmission type rear screen A as shown in FIG. In the molding blank part, roll mold 1
A concave or convex alignment mark 1c is formed by the two convex or concave alignment mark molding die 12c.

  In the subsequent second resin introduction pressurization step and second ultraviolet irradiation curing step, the ultraviolet curable resin layer 3 applied to the other surface of the base film layer 1 is irradiated with the convex mold roller 17 and the ultraviolet irradiation. When the ultraviolet curable resin layer 3 is cured as the convex portion 3 while being molded by irradiation of the means 19, the concave shape formed in the blank portion of the lenticular lens array layer 2 of the transmission type rear screen A shown in FIG. Alternatively, the convex alignment mark 1c may be colored so that it can be confirmed through the convex or concave alignment mark molding die portion 17c of the convex portion molding roll mold 17 (through the base film 1). ), The ultraviolet curable resin layer 3 is cured as the convex portion 3 while being molded.

The fragmentary sectional side view of the transmission type rear screen of this invention. The top view seen from the lens array layer side of the transmission type rear screen of this invention. The top view seen from the convex-shaped part side of the transmission type rear screen of this invention. The side view explaining the manufacturing process of the transmission type rear screen of this invention, and its manufacturing apparatus. The fragmentary sectional side view explaining the manufacturing process of the transmission type rear screen of this invention. The fragmentary sectional side view explaining the manufacturing process of the transmission type rear screen of this invention. The fragmentary sectional side view explaining the manufacturing process of the transmission type rear screen of this invention. The side view of the roll mold for lens array shaping | molding used for the manufacturing process of the transmission type rear screen of this invention, and the alignment in the manufacturing apparatus. The side view of the roll mold for convex part shaping | molding used for the manufacturing process of the transmission type rear screen of this invention, and the alignment in the manufacturing apparatus. The top view of the transmission type rear screen explaining the alignment in manufacture of the transmission type rear screen of this invention.

Explanation of symbols

L ... Projection light A ... Transmission type rear screen C ... Cutting line X ... Base film layer feed direction h ... Convex part height t ... Condensing width s1 ... Light shielding layer (convex part) width s2 ... Non Width p of the light shielding part ... Lens pitch 1 ... Base film layer 1a ... Condensing part 1c ... Alignment mark 2 ... Lenticular lens array layer 3 ... Convex part 4 ... Light shielding layer 12 ... Roll mold 12a for lens array molding ... Rotation Support shaft 12b ... Lens array molding die 12c ... Alignment mark molding die 17 ... Lens array molding roll mold 17a ... Rotating spindle 17b ... Lens array molding die 17c ... Alignment mark molding die

Claims (2)

  A lenticular lens array layer 2 is provided on one surface of the base film layer 1, and a convex portion 3 having a predetermined width is provided on a portion other than the light condensing portion of the lenticular lens array layer 2 on the other surface of the base film layer 1. A transmissive rear screen comprising a light shielding layer 4 on the top surface of the convex portion 3.   A first resin application step of applying an ultraviolet curable resin to one surface of the base film layer 1, and adding the base film layer 1 and the applied ultraviolet curable resin layer 2 to a roll mold for forming a lenticular lens array A resin introduction pressurizing step for introducing and pressurizing between the pressure roll and the resin layer by irradiating ultraviolet rays while sandwiching the ultraviolet curable resin layer 2 between the base film layer 1 and the roll mold; An ultraviolet irradiation curing process for curing 2, a resin peeling process for peeling the resin layer 2 cured as the base film layer 1 and the lenticular lens array layer 2 from a roll mold for forming a lenticular lens array, and the peeled base A second resin coating step in which an ultraviolet curable resin is applied to the other surface of the material film layer 1, and the base film layer 1 and the applied ultraviolet curable resin layer 3 are pressed against a roll mold for forming a convex portion Low A second resin introduction and pressurizing step that introduces and pressurizes the resin, and irradiates the resin with ultraviolet rays while sandwiching the ultraviolet curable resin layer 3 between the base film layer 1 and the roll mold. A second ultraviolet radiation curing step for curing the layer 3, and a second resin peeling step for peeling the base film layer 1 and the resin layer 3 cured as the convex portion 3 from the roll mold for forming the convex portion. And a light shielding layer forming step of forming a light shielding layer 4 by applying a light shielding ink to the top surface cured as the convex portion 3.

Images