JP2007264274A - Method for manufacturing total reflection type fresnel lens sheet with black matrix - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To highly accurately form a black matrix at a light non-transmission part of a light projection surface of a total reflection type Fresnel lens sheet. <P>SOLUTION: The total reflection type Fresnel lens sheet with the black matrix is manufactured by arranging a photosensitive resin layer 5 on the light projection surface of the total reflection type Fresnel lens sheet 2; forming an exposed part and an unexposed part on the photosensitive resin layer 5 by exposing the photosensitive resin layer 5 from a light incident surface side of the total reflection type Fresnel lens sheet 2 by using an optical modulator 7 which performs dimming so that an irradiation quantity distribution on an arrangement surface of the photosensitive resin layer 5 becomes uniform or a desired light quantity distribution; and forming the black matrix 4 at the unexposed part. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method of manufacturing a total reflection type Fresnel lens sheet with a black matrix.

  2. Description of the Related Art Rear projection televisions that enlarge and project an optical image from a projector such as a CRT or a liquid crystal device onto a rear projection screen with a projection lens so that a large screen image can be obtained have become widespread.

  A rear projection screen generally includes a Fresnel lens sheet that directs image light from a projection lens in the direction of an observer, and a lenticular lens sheet that diffuses light from the Fresnel lens sheet horizontally or vertically to widen the viewing angle. I have.

  In recent years, rear projection televisions have been designed to project image light from a projector at a large incident angle from an oblique direction with respect to a screen in response to a request for a reduction in thickness, and as a suitable Fresnel lens sheet, a total reflection type is projected. A Fresnel lens sheet is known (Patent Document 1).

  In addition, it has been proposed to improve the contrast by providing a black matrix that absorbs external light in the light non-transmissive portion of the light exit surface of such a Fresnel lens sheet (Patent Document 2).

  On the other hand, conventionally, a black matrix that prevents external light reflection and improves contrast in a rear projection screen is generally provided on the light exit surface of a lenticular lens sheet located on the viewer side. As another method, a method of forming a light shielding pattern using a difference in adhesiveness between an exposed portion and a non-exposed portion of a photosensitive resin is known (Patent Document 3).

Japanese Patent Laid-Open No. 61-208041 JP 60-173533 A JP 59-121033

  However, as shown in FIG. 3, as a Fresnel lens sheet 2 of a rear projection screen 10 used in a rear projection television having a large incident angle of image light from the projector 1 as shown in FIG. When a lens sheet is used and the black matrix 4 is formed on the light non-transmissive portion 2a of the light emitting surface by utilizing the difference in adhesiveness between the exposed portion and the non-exposed portion of the photosensitive resin, the following is performed. There was a problem. In FIG. 3, reference numeral 3 denotes a lenticular lens sheet.

  That is, according to this method, as shown in FIG. 5, a photosensitive adhesive layer that loses its adhesiveness upon exposure is formed as a photosensitive resin layer 5 on the light exit surface of the Fresnel lens sheet 2, and a rear projection television is provided. The light source 6 is placed at the same position as the projector 1 in the above, the light transmitting portion 2b on the light emitting surface of the Fresnel lens sheet 2 is exposed and cured, and transfer paper is applied to the unexposed adhesive portion of the light non-transmitting portion 2a. The black matrix 4 is formed by transferring the black transfer layer. In this case, in the Fresnel lens sheet 2 at the time of exposure, a dose distribution is generated that is high near the light source 6 and decreases as the distance from the light source 6 increases. Since the light source 6 is placed at the same position as the projector 1, this irradiation amount distribution becomes more prominent as the incident angle of the image light projected from the projector 1 onto the rear projection screen 10 increases as the rear projection television becomes thinner. become.

  Therefore, as shown in FIG. 4, the width of the black matrix 4 differs depending on the dose distribution, and cannot be accurately formed to the desired width.

  On the other hand, an object of the present invention is to make it possible to form a black matrix with high accuracy in the light non-transmissive portion of the light emitting surface of the total reflection type Fresnel lens sheet.

  The present invention provides a light modulation element for forming a black matrix in a light non-transmissive portion of a light exit surface of a total reflection type Fresnel lens sheet by utilizing a difference in characteristics between an exposed portion and a non-exposed portion of a photosensitive resin layer. When the exposure light is corrected with the tone, the exposure light dose distribution on the Fresnel lens sheet can be adjusted to the desired light intensity distribution including homogenization, and the expected black matrix can be accurately formed. The present invention has been completed by finding out what can be done.

  That is, the present invention provides a light modulation element in which a photosensitive resin layer is disposed on the light exit surface of a total reflection type Fresnel lens sheet, and the irradiation amount distribution on the surface on which the photosensitive resin layer is disposed is adjusted to a desired distribution. In this case, the photosensitive resin layer is exposed from the light incident surface side of the total reflection type Fresnel lens sheet to form an exposed portion and a non-exposed portion on the photosensitive resin layer, and a black matrix is formed on the non-exposed portion. A method for producing a total reflection type Fresnel lens sheet with a matrix is provided, and a total reflection type Fresnel lens sheet with a black matrix produced by this method is provided.

  According to the present invention, when the black matrix is formed in the light non-transmissive portion of the light emitting surface of the total reflection type Fresnel lens sheet by utilizing the difference in the characteristics of the exposed portion and the non-exposed portion of the photosensitive resin layer, The tone of exposure light is corrected using a modulation element, and the irradiation dose distribution on the surface of the photosensitive resin layer is made uniform, and the desired light distribution is adjusted, so the width of the black matrix depending on the dose can be managed arbitrarily. This makes it possible to accurately form the desired black matrix.

  Hereinafter, the present invention will be described in detail with reference to the drawings. In each figure, the same numerals indicate the same or equivalent components.

  In the method for producing a total reflection type Fresnel lens sheet with a black matrix of the present invention, first, a photosensitive resin layer is disposed on a flat light emitting surface of the total reflection type Fresnel lens sheet.

  Here, as the total reflection type Fresnel lens sheet, a publicly known one can be used, and examples of the constituent resin material include light-transmitting resins such as acrylic resin, styrene resin, polycarbonate resin, and epoxy resin. be able to. Examples of the production method include an ultraviolet curable resin method, a casting method, and a hot press method.

  Further, the total reflection type Fresnel lens sheet is preferably formed of a total reflection type Fresnel lens having a Fresnel lens pitch of 50 to 500 μm, and has a lens shape in which all incident light is totally reflected on the total reflection surface.

  As the photosensitive resin layer disposed on the light exit surface of the total reflection type Fresnel lens sheet, a photosensitive adhesive layer that loses adhesiveness upon exposure, a photocurable resin layer that becomes a black cured layer upon exposure, or the like is used. be able to. As a specific usage mode of the photosensitive adhesive layer, a laminated film in which the photosensitive adhesive layer is sandwiched between a support film and a release film (for example, a DUPONT chloromarin film) can be exemplified.

  The arrangement method of the photosensitive resin layer can be performed by sticking a photosensitive resin formed into a film, spinner coating, roll coating, bar coating, or the like of a photosensitive resin prepared in a liquid state.

  After disposing the photosensitive resin layer on the total reflection type Fresnel lens sheet, as shown in FIG. 1, the photosensitive resin layer 5 is placed on the light incident surface side of the total reflection type Fresnel lens sheet 2 (that is, the photosensitive resin layer). The exposure is performed from the side opposite to the arrangement surface 5. When this exposure is performed with visible light, the position of the exposure light source 6 is preferably the same position as the projector when the total reflection type Fresnel lens sheet 2 is actually used in a rear projection television or the like. Also, when exposing with light other than visible light, depending on the wavelength of the exposure light, depending on the difference in refractive index of the resin material constituting the total reflection type Fresnel lens sheet, the same position as when exposing with visible light. It is preferable to appropriately adjust the position of the exposure light source 6 so that the exposure light passes.

  Further, at the time of this exposure, a light modulation element 7 that adjusts the irradiation amount distribution on the arrangement surface of the photosensitive resin layer 5 to make the other desired light quantity distribution uniform, and the irradiation amount on the arrangement surface of the photosensitive resin layer 5 is used. However, regardless of the distance from the light source 6 for exposure, a desired or arbitrary desired dose distribution is set.

  The light modulation element 7 is a reflection type light modulation element (Texas Instruments, DMD (digital micromirror device), which modulates the light beam emitted from the light source by controlling the incident angle of the micromirror, and applied to the liquid crystal. Examples include a liquid crystal cell that controls light transmittance by adjusting voltage, an ND filter in which light transmittance is formed so as to cancel the dose distribution, a gradation mask, etc. In particular, a reflective light modulation element or liquid crystal The use of a cell is preferable because the dose distribution can be actively controlled.

  The exposure light source 6 can be appropriately selected according to the exposure wavelength of the photosensitive resin layer 5. For example, when exposure is performed with ultraviolet rays, a mercury lamp, a halogen lamp, or the like is used.

  With this exposure, when the total reflection type Fresnel lens sheet is actually used in a rear projection television or the like, the light transmitting portion 2b on the light emitting surface is exposed, for example, with a uniform dose, and the light non-transmitting portion 2a is not exposed. Part.

  After the exposure, a black matrix is formed in the non-exposed part according to the type of the photosensitive resin layer 5. For example, when a photosensitive adhesive layer (DUPONT chloromarine film) that loses its adhesiveness upon exposure is used as the photosensitive resin layer 5, after exposure, the adhesive layer 1 first loses its adhesiveness at the light transmitting portion 2 b. The resin layer is peeled off together with the support film, and the toner is attached to the adhesive portion remaining in the light non-transmissive portion 2a, or the black transfer layer is transferred from the transfer paper having the black transfer layer, and the black matrix 4 is removed. Form.

  In addition, when a photocurable resin layer that becomes a light-shielding cured layer by exposure is used as the photosensitive resin layer 5, after the exposure, the resin layer that has been cured by exposure in the light transmission portion 2 b is peeled off, An uncured resin layer is left in the light non-transmissive portion 2a. Subsequently, it exposes from the light-projection surface side of the total reflection type | mold Fresnel lens sheet 2, the uncured resin layer which remained in the light non-transmissive part 2a is hardened, and it is set as a light shielding layer.

  In this way, as shown in FIG. 2, the black matrix 4 can be formed with high accuracy in the light non-transmissive portion 2a of the light emitting surface of the total reflection type Fresnel lens sheet 2.

  INDUSTRIAL APPLICABILITY The present invention is useful as a method for providing a black matrix on a total reflection type Fresnel lens sheet, and the total reflection type Fresnel lens sheet with a black matrix obtained by this method can be suitably used in a rear projection television or the like. .

It is explanatory drawing of the exposure method in the case of manufacturing a total reflection type | mold Fresnel lens sheet with a black matrix by this invention. It is sectional drawing of a total reflection type Fresnel lens sheet with a black matrix. It is a schematic diagram of a general rear projection type television. It is a figure which shows the problem in the case of forming a black matrix in a total reflection type Fresnel lens sheet by the conventional method. It is explanatory drawing of the exposure method in the case of manufacturing a total reflection type | mold Fresnel lens sheet with a black matrix by the conventional method.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Projector 2 Fresnel lens sheet or total reflection type Fresnel lens sheet 2a Light non-transmission part 2b Light transmission part 3 Lenticular lens sheet 4 Black matrix 5 Photosensitive resin layer 6 Light source 7 Light modulation element 10 Rear projection type screen

Claims (5)

  Using a light modulation element that arranges a photosensitive resin layer on the light exit surface of the total reflection type Fresnel lens sheet and adjusts the irradiation amount distribution on the surface of the photosensitive resin layer to a desired distribution, a total reflection type Total reflection type Fresnel with a black matrix that forms an exposed portion and a non-exposed portion on the photosensitive resin layer by exposing the photosensitive resin layer from the light incident surface side of the Fresnel lens sheet, and forms a black matrix in the non-exposed portion. A manufacturing method of a lens sheet.   2. The method for producing a total reflection type Fresnel lens sheet with a black matrix according to claim 1, wherein DMD is used as the light modulation element.   2. The method for producing a total reflection type Fresnel lens sheet with a black matrix according to claim 1, wherein a liquid crystal cell is used as the light modulation element.   The manufacturing method of the total reflection type | mold Fresnel lens sheet with a black matrix in any one of Claims 1-3 which arrange | positions the photosensitive adhesive layer which loses adhesiveness by exposure as a photosensitive resin layer. A total reflection type Fresnel lens sheet with a black matrix manufactured by the method according to claim 1.

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