JP2012159646A - Method for manufacturing transmissive curved surface screen and method for manufacturing display device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a transmissive curved surface screen, by which a transmissive curved surface screen can be easily manufactured, the screen having improved designing property as the screen is formed to have a three-dimensional curved surface, and to provide a method for manufacturing a display device having a transmissive curved surface screen with improved designing property by forming the screen into a three-dimensional curved surface.SOLUTION: The method for manufacturing a transmissive curved surface screen and a display device comprises a method for manufacturing a screen, which includes a laminate for controlling light from an image light source and transmitting the light to an observer's side, and a Fresnel lens layer, and which is curved to form a three-dimensional curved surface. The method includes: a laminate producing step of producing a laminate in a planar state; a step of preliminarily molding the planar laminate produced in the laminate producing step; and an injection molding step of forming a Fresnel lens layer on one surface side of the laminate molded in the preliminary molding step by using an injection molding die having grooves of a pattern corresponding to the Fresnel lens, and curving the laminate and the Fresnel lens layer to form a three-dimensional curved surface.

Description

  The present invention relates to a method of manufacturing a transmissive curved screen that is formed to form a three-dimensional curved surface and transmits image light projected from one surface side to the other surface side, and a method of manufacturing the transmissive curved screen. The present invention relates to a method for manufacturing the display device used.

  Conventionally, display devices capable of displaying various images have been incorporated into various systems. In recent years, the field of systems to which display devices are applied has further expanded, and display devices have been incorporated into systems related to daily life. For example, display devices have been applied to fields in which designability is very important, such as automobiles and amusement machines. A display device applied to such a field is not only expected to have a function of displaying an image, but is also required to be harmonized with the entire system from the viewpoint of design.

  In Patent Document 1, it has been studied to curve the image display surface of a liquid crystal display device that has become the mainstream of display devices in recent years. However, as described in paragraph 0004 of Patent Document 1, a liquid crystal display panel of a liquid crystal display device is usually configured to include glass, and considerable contrivance is required even if it is slightly curved. . In view of such a situation, the design of display devices that are actually used has been improved exclusively by adding features to the frame or casing that surrounds the video display surface.

JP 2009-63701 A

  However, it is difficult to impart sufficient designability to the display device simply by devising the frame and the housing.

  Therefore, in view of the above problems, the present invention can easily manufacture a transmission type curved screen having improved design by forming a three-dimensional curved surface. It is an object of the present invention to provide a method for manufacturing a display device including a transmissive curved screen with improved design by forming an original curved surface.

  The present invention will be described below. In order to facilitate understanding of the present invention, reference numerals in the accompanying drawings are appended in parentheses, but the present invention is not limited to the illustrated embodiment.

  The invention according to claim 1 is a laminate (31) having a light diffusion layer (20) capable of diffusing and emitting light incident from an image light source (3) to the viewer side, and an image light source of the laminate. A transmissive curved screen (10) bent so as to form a three-dimensional curved surface, including a base material layer (32) formed on the side, wherein the laminated body is produced in a flat plate shape Preliminary molding in the pre-molding step using the pre-molding step (S2) and the injection mold (70) for pre-molding the plate-like laminate produced in the production step (S1) and the laminate manufacturing step. Forming a base material layer on the image light source side surface of the laminated body, and bending the laminated body and the base material layer so as to form a three-dimensional curved surface. It is a manufacturing method.

  Invention of Claim 2 is a manufacturing method of the transmissive | pervious curved screen (10) of Claim 1, The base material layer (32) has a Fresnel lens (24) in the observer side, Video of the laminate (31) preformed in the pre-molding step (S2) using the injection mold (70) having the groove (73) shaped corresponding to the Fresnel lens in the injection molding step (S3) A base material layer is formed on the surface on the light source side, and the laminate and the base material layer are bent so as to form a three-dimensional curved surface.

  The invention according to claim 3 is the method of manufacturing the transmissive curved screen (10) according to claim 1 or 2, wherein the laminated body (31) is arranged in parallel along the sheet surface so as to transmit light. An optical functional layer (12) having a transmission part (13) and a light absorption part (14) arranged in parallel so as to be able to absorb light between the light transmission parts is provided. The method includes a step of forming a functional layer.

  Invention of Claim 4 is a manufacturing method of the transmissive | pervious curved screen in any one of Claims 1-3 WHEREIN: A preforming process (S2) heats a laminated body (31), and has desired shape. Is a step of molding a laminate using the molds (50, 60) obtained, and the molding is performed by vacuum contact, pressure contact, or vacuum / pressure formation.

  “Vacuum adhesion” means that the atmosphere between the laminate and the mold is reduced in pressure to adhere the laminate to the mold. Further, “pressure contact” means that the laminate is pressed against the mold by pressurization using gas pressure, and the laminate is brought into close contact with the mold. Furthermore, “vacuum and pneumatic molding” means that the laminate is molded by pressing the laminate against the mold by pressurization using gas pressure while reducing the atmosphere between the laminate and the mold. To do.

  According to a fifth aspect of the present invention, in the method of manufacturing a transmissive curved screen according to the fourth aspect, the mold (60) used in the preforming step (S2) is a male type.

  Invention of Claim 6 is a manufacturing method of the transmissive | pervious curved screen in any one of Claims 1-3 WHEREIN: A preforming process (S2) heats a laminated body (31), and has desired shape. It is the process of press-molding a laminated body using the metal mold | die from which this is obtained.

  The invention according to claim 7 is the method of manufacturing a transmissive curved screen according to any one of claims 1 to 6, wherein the mold used in the preforming step (S2) is an oval or circular projection in plan view. It has a molding part composed of a part or a recess, and the laminate is preformed using the molding part.

  According to an eighth aspect of the present invention, in the manufacturing method of the transmissive curved screen according to the seventh aspect, the mold used in the pre-forming step (S2) includes at least one row in which a plurality of molded portions are arranged. In a plan view, the molding parts adjacent in the row are formed so that a part of each other overlaps.

  According to the ninth aspect of the present invention, the transmissive curved screen (10) bent so as to form a three-dimensional curved surface, the image light source (3) for emitting image light, the transmissive curved screen and the image light source are supported. And a housing (2) for housing the image display device (1), wherein the transmissive curved screen diffuses light incident from the image light source toward the viewer and emits the light. A laminate manufacturing step (S1) including a laminate (31) having a layer (20) and a base material layer (32) formed on the video light source side of the laminate, and producing the laminate in a flat plate shape. ) And a pre-molding step (S2) for preforming the flat laminate produced in the laminate production step, and an image light source of the laminate preformed in the preforming step using an injection mold Form a base material layer on the side surface and laminate Bending the base material layer to form the three-dimensional curved surface, an injection molding step (S3), a step of manufacturing a transmissive curved screen, and a step of incorporating the image light source and the transmissive curved screen into the housing , A method for manufacturing a display device.

  According to the method for manufacturing a transmissive curved screen of the present invention, it is possible to easily manufacture a transmissive curved screen having improved design by forming a three-dimensional curved surface. In addition, according to the method for manufacturing a display device of the present invention, a display device including a transmissive curved screen with improved design by forming a three-dimensional curved surface can be easily manufactured.

It is the perspective view which represented typically the external appearance of the transmission type curved screen manufactured by the manufacturing method of the transmission type curved screen of this invention concerning one embodiment. It is the figure which showed the cross section of the transmissive | pervious curved screen shown in FIG. 1, and represented the layer structure typically. It is the figure which represented typically the cross section of the display apparatus provided with the transmissive | pervious curved screen shown in FIG. It is the figure which expanded the part of the Fresnel lens layer and represented typically the optical path of the image light which injected into the Fresnel lens. FIG. 5A is a plan view schematically showing a Fresnel lens when an example of the Fresnel lens layer is made flat. FIG. 5B is a plan view schematically showing a Fresnel lens when another example of the Fresnel lens layer is formed into a flat plate shape. It is the top view which represented typically the Fresnel lens at the time of making it flat form about the other example of a Fresnel lens layer. It is the figure which expanded and showed a part of optical function layer shown in FIG. It is the flowchart which showed the process which the manufacturing method of the transmissive | pervious curved screen of this invention has. It is sectional drawing which represented a part of process typically about an example of the manufacturing method of an optical function layer. It is the perspective view which represented typically another process about an example of the manufacturing method of an optical function layer. FIG. 11A is a cross-sectional view schematically showing a part of the process for an example of the preforming process. FIG. 11B is a cross-sectional view schematically showing the next step of the step shown in FIG. FIG. 11C is a cross-sectional view schematically showing the next step of the step shown in FIG. FIG. 12A is a cross-sectional view schematically showing a part of the process in another example of the preforming process. FIG. 12B is a cross-sectional view schematically showing the next step of the step shown in FIG. FIG. 12C is a cross-sectional view schematically showing the next step of the step shown in FIG. It is sectional drawing which represented typically an example of the injection molding process. It is the figure which represented typically the cross section about the other example of the display apparatus provided with the transmissive | pervious curved screen shown in FIG. FIG. 15A is a perspective view schematically showing an example of a mold used for preforming. FIG. 15B is a diagram schematically showing a cross section of the mold at XVb-XVb shown in FIG. FIG.15 (c) is a figure which shows schematically the cross section of the metal mold | die in XVc-XVc shown to Fig.15 (a). FIG. 16A is a perspective view schematically showing another example of a mold used for preforming. FIG.16 (b) is a figure which shows schematically the cross section of the metal mold | die in XVIb-XVIb shown to Fig.16 (a). FIG.16 (c) is a figure which shows schematically the cross section of the metal mold | die in XVIc-XVIc shown to Fig.16 (a). FIG. 17A is a perspective view schematically showing another example of a mold used for preforming. FIG. 17B is a diagram schematically showing a cross section of the mold at XVIIb-XVIIb shown in FIG. FIG. 17C is a diagram schematically showing a cross section of the mold at XVIIc-XVIIc shown in FIG.

  The above-described operation and gain of the present invention will be clarified from embodiments for carrying out the invention described below. Hereinafter, the present invention will be described based on embodiments shown in the drawings. In the drawings, for convenience of illustration and easy understanding, the scale and vertical / horizontal dimensional ratios are appropriately changed from those of the actual ones and exaggerated. Moreover, in each drawing, the code | symbol which becomes repeated may be abbreviate | omitted for visibility.

<Transparent curved screen>
FIG. 1 is a perspective view schematically showing the appearance of a transmissive curved screen 10 (hereinafter simply referred to as “screen 10”) manufactured by the transmissive curved screen manufacturing method of the present invention according to one embodiment. FIG. In FIG. 1, when the screen 10 is provided in a display device, the side on which the image light from the image light source is projected (hereinafter simply referred to as “image light source side”) is the back side of the paper surface. When the display device is provided, the side observed by the observer (hereinafter simply referred to as “observer side”) is the front side of the page. Further, the “horizontal direction” shown in FIG. 1 is a horizontal direction when the screen 10 is provided in the display device, and the “vertical direction” is a case where the screen 10 is provided in the display device. The direction is vertical. FIG. 2 is a diagram showing a cross section of the screen 10 and schematically showing the layer structure. In FIG. 2, the right side of the drawing is the image light source side, and the left side of the drawing is the viewer side. FIG. 2 is a diagram schematically showing the layer configuration of the screen 10 simply, and shows the screen 10 in a flat plate shape different from the actual shape. FIG. 3 is a diagram schematically showing a vertical section of the display device 1 including the transmissive curved screen 10.

  As shown in FIG. 1, the screen 10 is formed to have a three-dimensional curved surface that is convex toward the viewer. Here, “formed so as to form a three-dimensional curved surface” means that it is bent partially or entirely around a plurality of axes inclined with respect to each other. Specifically, the screen 10 has a shape that becomes a rectangle when flattened, and is centered on a first axis A1 that is parallel to one of the diagonal lines of the rectangle and is positioned on the image light source side of the screen 10. In addition to being bent in the direction d1, it is also bent in a direction d2 centered on a second axis A2 that is located on the image light source side of the screen 10 in parallel with the other diagonal line and intersects the first axis A1. As a result, the screen 10 is formed so as to form a three-dimensional curved surface that is convex toward the viewer as a whole. Moreover, the display surface 10a of the screen 10 protrudes most to the observer side in the center position Pa where a pair of rectangular diagonal lines at the time of making the screen 10 flat form. However, the shape of the transmissive curved screen that can be manufactured by the method of manufacturing the transmissive curved screen of the present invention is not limited to the shape of the screen 10, and the transmissive curved screen is manufactured to form various three-dimensional curved surfaces. Can do. Moreover, the shape when the transmissive curved screen is formed into a flat plate is not limited to a rectangle, and can be various shapes.

  The screen 10 is a screen that transmits image light projected from the image light source side to the viewer side. Therefore, as shown in FIG. 3, when the screen 10 is incorporated in the display device 1, the display device 1 includes the screen 10, a housing 2 having an opening for supporting the screen 10, and the housing 2. And a so-called rear projection display device that includes at least the image light source 3 that projects the image light L onto the screen 10.

  As shown in FIG. 2, the screen 10 includes a laminate 31 and a base material layer 32. The laminated body 31 is a layer that can control the light from the image light source and transmit the light to the viewer side, and has a plurality of layers. The laminated body 31 shown in FIG. 2 includes a hard coat layer 21, a light diffusion layer 20, an optical functional layer 12, and a layer serving as a base material of the optical functional layer 12 (hereinafter, a layer serving as a base material of the optical functional layer 12). (Referred to as “first base material layer”). In the present embodiment, since the base material layer 32 includes the Fresnel lens 24, the base material layer 32 is hereinafter referred to as the Fresnel lens layer 32. Hereinafter, these layers will be described.

(Fresnel lens layer 32)
As will be described later, the Fresnel lens layer 32 is a layer in which the base 23 and the Fresnel lens 24 formed on the base 23 are integrally formed of a resin. Examples of the resin constituting the Fresnel lens layer 32 include transparent resins such as acrylic resin, styrene resin, polyester resin, polycarbonate resin, and acrylic-styrene copolymer resin.

  The base 23 is a portion provided to give the Fresnel lens layer 32 a certain level of strength. The thickness of the base 23 (the thickness of the portion of the Fresnel lens layer 32 excluding the Fresnel lens 24. That is, the thickness of the thinnest portion of the Fresnel lens layer 32) is preferably 3 mm or more and 5 mm or less. By setting the thickness of the base portion 23 to 3 mm or more, it becomes easy to impart sufficient rigidity to the Fresnel lens layer 32. On the other hand, by setting the thickness of the base 23 to 5 mm or less, it is easy to prevent problems such as the screen 10 becoming too thick, the transmittance of image light being lowered, and ghost (double image) being generated. Become.

  The Fresnel lens 24 has a function of deflecting the traveling direction of the image light projected on the screen 10 as a divergent light beam from the image light source. Specifically, the Fresnel lens 24 converts image light incident as a divergent light beam into a parallel light beam that travels from the image light source side toward the viewer side. In this way, once the image light is converted into a parallel light flux, variations in the brightness of the image observed from the viewer side can be reduced.

  The optical path of the image light incident on the Fresnel lens 24 will be described with reference to FIG. FIG. 4 is a diagram showing an optical path of image light incident on the Fresnel lens 24 while enlarging a part of the Fresnel lens layer 32.

  As shown in FIG. 4, the plurality of unit lenses 25 constituting the Fresnel lens 24 include an incident surface 26 that refracts and enters the image light L, and an image viewer L that totally reflects the image light L incident from the incident surface 26. And a total reflection surface 27 directed to the side. As described above, the image light L emitted from the image light source is projected on the screen 10 as a divergent light beam, enters the funnel lens layer 32, and is refracted and reflected by the unit lenses 25, 25,... Constituting the Fresnel lens 24. As a result, the luminous flux is converted into a parallel light beam and enters the laminated body 31.

  Examples of the structure of the unit lens constituting such a Fresnel lens 24 will be given below. FIG. 5A, FIG. 5B, and FIG. 6 are plan views schematically showing the Fresnel lens 24 when the Fresnel lens layer 32 is formed in a flat plate shape. FIGS. 5A and 5B show so-called circular Fresnel lenses, and FIG. 6 shows a so-called linear Fresnel lens. In FIG. 5A, FIG. 5B, and FIG. 6, the back of the paper is the observer side, and the front of the paper is the video light source side. Further, “horizontal direction” and “vertical direction” shown in FIGS. 5A, 5B, and 6 are synonymous with FIG.

  The unit lenses 25a, 25a,... Constituting the Fresnel lens 24a shown in FIG. 5A are arranged so as to extend on an arc of a concentric circle. Further, the configuration of the unit lenses 25a, 25a,... In the horizontal direction is line symmetric with respect to an axis Aa parallel to the vertical direction passing through the center position in the horizontal direction. The configuration of the unit lenses 25a, 25a,... Can be designed based on the arrangement of the image light source and the like with respect to the screen 10. For example, the center O of the concentric circle related to the arrangement of the unit lenses 25a, 25a,... Is designed to overlap with the arrangement position of the image light source when the display device including the screen 10 is observed from the front. In this case, the center O may be referred to as the optical center of the Fresnel lens 24a. As described above, by decentering the center O from the center of the Fresnel lens layer 32 in the vertical direction, even when image light is projected from below the screen 10, the divergent light beam from the image light source can be made into a parallel light beam. . By adopting a configuration in which image light is irradiated from below the screen 10, the thickness of the display device including the screen 10 can be reduced.

  The Fresnel lens 24b shown in FIG. 5B is different from the Fresnel lens 24a shown in FIG. 5A in the position of the center O of the concentric circle regarding the arrangement of the unit lenses 25b, 25b,. . As in the Fresnel lens 24b shown in FIG. 5B, the center O of the concentric circle related to the arrangement of the unit lenses 25b, 25b,.

  The unit lenses 25c, 25c,... Constituting the Fresnel lens 24c shown in FIG. 6 extend linearly in the horizontal direction, and the unit lenses 25c, 25c,. As described above, the Fresnel lens 24 may be a so-called linear Fresnel lens. However, in the case of the linear Fresnel lens, the light can be converged in the arrangement direction of the unit lenses (in the form shown in FIG. 6, the vertical direction on the paper surface), but the direction in which the unit lens extends (in the form shown in FIG. (Direction) cannot converge light.

(First base material layer 11)
The 1st base material layer 11 is a layer used as the base material for forming the optical function layer 12 demonstrated in detail later, and the deformation | transformation of the laminated body 31 is suppressed and generation | occurrence | production of distortion of the image | video displayed by the screen 10 is produced. Rigidity that can be prevented is given. In addition, as described above, since the base portion 23 of the Fresnel lens layer 32 is thickened, there is a risk that a ghost (double image) may be generated. It is preferable to design the material and the thickness so that not only the body 31 has sufficient rigidity but also the entire screen 10 has sufficient rigidity.

  The first base material layer 11 is preferably made of, for example, the same resin as that constituting the Fresnel lens layer 32 described above. This is because the adhesion between the first base material layer 11 and the Fresnel lens layer 32 can be improved when the Fresnel lens layer 32 is formed by injection molding as will be described later.

  The thickness of the first base material layer 11 is preferably 50 μm or more and 200 μm or less. By setting the thickness of the first base layer 11 to 50 μm or more, it becomes easy to impart sufficient rigidity to the screen 10. On the other hand, when the thickness of the first base material layer 11 is set to 200 μm or less, the thickness of the screen 10 becomes too thick, the transmittance of the image light decreases, and the optical functional layer 12 is formed as described later. This makes it easier to prevent problems such as being difficult to do.

(Optical function layer 12)
The optical functional layer 12 is a layer having a function of appropriately absorbing stray light and external light while controlling the optical path of the image light incident from the image light source side. The optical functional layer 12 has a cross section shown in FIG. 2 and a shape extending to the back / near side of the drawing. FIG. 7 is an enlarged view of a part of the optical functional layer 12 shown in FIG. The optical functional layer 12 will be further described with reference to FIGS.

  The optical functional layer 12 includes light transmitting parts 13, 13,... Arranged in parallel along the layer surface so that light can be transmitted, and a light absorbing part 14 arranged in parallel so as to absorb light between the light transmitting parts 13, 13,. , 14,..., And the light transmitting portions 13, 13,... And the light absorbing portions 14, 14,... Have a shape that has the cross section shown in FIG. I have. The optical functional layer 12 includes the light transmitting portions 13, 13,... And the light absorbing portions 14, 14, so that the optical path of the image light incident from the image light source side when provided in the display device. It is possible to have a function of appropriately absorbing stray light and external light.

  The light transmitting portions 13, 13,... Are elements having a function of transmitting image light, and are elements having a substantially trapezoidal cross section in the cross sections shown in FIGS. An upper base and a lower base longer than the upper base in the substantially trapezoidal cross section are arranged in a direction along the layer surface of the optical functional layer 12. Further, the light transmitting portions 13, 13,... Have a refractive index of Np and have light transmittance. Such a light transmission part 13,13, ... can be comprised by hardening the light transmission part structure composition demonstrated below. The value of the refractive index Np is not particularly limited, but is preferably 1.49 to 1.56 from the viewpoint of the availability of the applied material.

  The light transmissive part constituting composition is preferably one that can be cured by light such as ultraviolet rays. For example, the following photocurable prepolymer (P1), reactive diluent monomer (M1), and photopolymerization initiator (S1) A photocurable resin composition containing the above is preferably used.

  Examples of the photocurable prepolymer (P1) include epoxy acrylate-based, urethane acrylate-based, polyether acrylate-based, polyester acrylate-based, and polythiol-based prepolymers.

  Examples of the reactive dilution monomer (M1) include vinyl pyrrolidone, 2-ethylhexyl acrylate, β-hydroxy acrylate, and tetrahydrofurfuryl acrylate.

  Examples of the photopolymerization initiator (S1) include hydroxybenzoyl compounds (2-hydroxy-2-methyl-1-phenylpropan-1-one, 1-hydroxycyclohexyl phenyl ketone, benzoin alkyl ether, etc.), benzoyl Formate compounds (such as methylbenzoylformate), thioxanthone compounds (such as isopropylthioxanthone), benzophenones (such as benzophenone), phosphate compounds (1,3,5-trimethylbenzoyldiphenylphosphine oxide, bis (2,4,6-) Trimethylbenzoyl) -phenylphosphine oxide and the like, and benzyldimethyl ketal and the like. Of these, 2-hydroxy-2-methyl-1-phenylpropan-1-one, 1-hydroxycyclohexyl phenyl ketone, and bis (2,4) are preferable from the viewpoint of preventing coloring of the light transmitting portions 13, 13,. , 6-trimethylbenzoyl) -phenylphosphine oxide. In addition, it is preferable that the said photoinitiator (S1) is contained 0.5 mass% or more and 5.0 mass% or less on the basis (100 mass%) of light transmission part structure composition whole quantity.

  These photocurable prepolymer (P1), reactive diluent monomer (M1) and photopolymerization initiator (S1) can be used alone or in combination of two or more. In addition, in the light transmitting part constituting composition, if necessary, silicone additives, rheology control agents, It is also possible to add a defoaming agent, a release agent, an antistatic agent, an ultraviolet absorber and the like. However, as will be described below, the light transmission part constituting composition is preferably an ultraviolet curable resin having an intercrosslinking molecular weight of 3000 or more and 4000 or less.

  The ultraviolet curable resin becomes soft (easily stretched) when the molecular weight between crosslinks is increased, and the shape of the soft ultraviolet curable resin is easily changed when molded. The present inventors conducted an experiment on the assumption that it is preferable to use a moderately soft ultraviolet curable resin in the present embodiment. As a result, an ultraviolet curable resin having a molecular weight between crosslinks of 3000 or more and 4000 or less is used. Has been found to be preferable. Below, an example of the experiment which the inventor performed is demonstrated.

  The inventor prepared a plurality of sheets each having an optical functional layer having a light transmitting portion formed of different resins, and molded the sheets to have a three-dimensional curved surface using various molds. Went. Table 1 shows the shape of the mold used in the experiment and the resin used. The resin used in this experiment is a resin having a molecular weight between crosslinks of 1500 (resin A) and a resin having a molecular weight between crosslinks of 3250 (resin B). Moreover, the metal mold | die used for this experiment is a metal mold | die as shown in FIG. 15 (a) is a perspective view of the mold 150, FIG. 15 (b) is a cross section taken along the line XVb-XVb shown in FIG. 15 (a), and FIG. 15 (c) is shown in FIG. 15 (a). It is the cross section by XVc-XVc shown. The “curvature radius” shown in Table 1 is the curvature radius in the longitudinal direction of the concave portion 151 of the mold 150. “Depth” is the depth D 1 of the recess 151. The “longitudinal change rate” is the length L2 of the arc 154 that forms the bottom in the longitudinal section of the recess 151 (the section shown in FIG. 15B), and the length L1 of the recess 151 in the longitudinal direction when viewed from above. Is a value obtained by (L2−L1) / L1. “Area change rate” is a value obtained by calculating the change rate in the short direction in the same manner as the change rate in the longitudinal direction and multiplying the change rate in the short direction and the change rate in the longitudinal direction. “Vertical stripe” indicates whether or not a crack has occurred when molding is performed such that the longitudinal direction of the light transmission portion (backward / frontward direction in FIG. 2) is parallel to XVb-XVb. “Stripe” indicates whether or not a crack has occurred when molding is performed such that the longitudinal direction of the light transmitting portion (the rear side / front side in FIG. 2) is parallel to XVc-XVc. In addition, when a crack generate | occur | produces, it is set as "(circle)" when a crack does not generate | occur | produce.

  As shown in Table 1, when an ultraviolet curable resin having a molecular weight between crosslinks of 3250 was used, no crack was generated even when the area change rate was extended to 19.4%.

  Next, the light absorbers 14, 14,... Will be described. The light absorbing portions 14, 14,... Are elements having a substantially trapezoidal surface in the cross section shown in FIGS. An upper base and a lower base longer than the upper base in the substantially trapezoidal cross section are arranged in a direction along the layer surface of the optical functional layer 12. In addition, a surface corresponding to the lower base of the substantially trapezoidal cross section is arranged in parallel between the upper bases of the light transmitting portions 13, 13,. And one surface of the optical functional layer 12 is formed by the lower base of the light absorption parts 14, 14,... And the upper base of the light transmission parts 13, 13,. The hypotenuse in the substantially trapezoidal cross section preferably forms an angle of 0 degrees or more and 10 degrees or less with respect to the normal direction of the layer surface of the optical function layer 12. When the angle of the hypotenuse is close to 0 degrees, the cross section is substantially rectangular. Further, the inclination of the oblique sides of the light absorbing portions 14, 14,... Is not necessarily constant, and may be a polygonal line or a curved line. Furthermore, the light absorbing portions 13, 13,... May have a substantially triangular cross section.

  Further, the light absorbing portions 14, 14,... Are made of a predetermined material having a refractive index Nb smaller than the refractive index Np of the light transmitting portions 13, 13,. In this way, by setting the refractive index Np of the light transmitting portions 13, 13... And the refractive index Nb of the light absorbing portions 14, 14,... To Np> Nb, the image light source incident on the light transmitting portions 13, 13,. Are reflected by Snell's law at the interface between the light absorbing parts 14, 14,... And the light transmitting parts 13, 13,. The difference in refractive index between Np and Nb is not particularly limited, but is preferably greater than 0 and 0.06 or less.

  Further, in the present embodiment, the relationship of Np> Nb is preferable as described above, but is not necessarily limited to this, and the refractive index of the light transmission part and the refractive index of the light absorption part may be the same. It is also possible to make the refractive index of the light transmission part smaller than the refractive index of the light absorption part.

  In addition, the light-absorbing part 14, 14,... In the present embodiment is a light-absorbing part-constituting composition comprising the light-absorbing particles 16, 16,... And the binder 15 in which the light-absorbing particles 16, 16,. It is configured by filling a groove between the light transmitting portions 13, 13,. As a result, the image light incident on the inner side of the light absorbing portions 14, 14, and so on without being reflected by Snell's law at the interface between the light transmitting portions 13, 13, and so on and the light absorbing portions 14, 14,. It can be absorbed by the particles 16, 16,. Furthermore, the external light from the observer side incident at a predetermined angle can be appropriately absorbed by the light absorbing particles 16, 16,..., And the contrast of the image can be improved.

  At this time, the binder 15 is made of the material having the refractive index Nb. Although what is used as the said binder is not specifically limited, What is hardened | cured by light, such as an ultraviolet-ray, is preferable, for example, a reactive dilution monomer (M2) and photopolymerization start to a photocurable prepolymer (P2) A photocurable resin composition containing the agent (S2) is preferably used.

  Examples of the photocurable prepolymer (P2) include urethane (meth) acrylate, polyester (meth) acrylate, epoxy (meth) acrylate, and butadiene (meth) acrylate.

  Examples of the reactive dilution monomer (M2) include monofunctional monomers such as N-vinyl pyrrolidone, N-vinyl caprolactone, vinyl imidazole, vinyl pyridine, styrene, and other vinyl monomers, lauryl (meth) acrylate, stearyl ( (Meth) acrylate, butoxyethyl (meth) acrylate, ethoxydiethylene glycol (meth) acrylate, methoxytriethylene glycol (meth) acrylate, methoxypolyethylene glycol (meth) acrylate, methoxydipropylene glycol (meth) acrylate, paracumylphenoxyethyl (meth) ) Acrylate, nonylphenoxy polyethylene glycol (meth) acrylate, tetrahydrofurfuryl (meth) acrylate, isobornyl (meth) a (Meth) acrylic acid ester monomers such as relate, cyclohexyl (meth) acrylate, benzyl methacrylate, N, N-dimethyl (meth) acrylamide, N, N-dimethylaminopropyl (meth) acrylate, acryloylmorpholine, A (meth) acrylamide derivative is mentioned. Polyfunctional monomers include ethylene glycol di (meth) acrylate, diethylene glycol di (meth) acrylate, triethylene glycol di (meth) acrylate, polyethylene glycol di (meth) acrylate, tripropylene glycol di (meth) acrylate, polytetra Methylene glycol di (meth) acrylate, 1,4-butanediol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, 1,9-nonanediol di (meth) acrylate, 3-methyl-1, 5-pentanediol di (meth) acrylate, neopentyl glycol di (meth) acrylate, dimethylol-tricyclodecane di (meth) acrylate, hydroxypivalate neopentyl glycol di (meth) acrylate Bisphenol A polypropoxydiol di (meth) acrylate, trimethylolpropane tri (meth) acrylate, ethoxylated trimethylolpropane tri (meth) acrylate, propoxylated trimethylolpropane tri (meth) acrylate, pentaerythritol tri (meth) Acrylate, glyceryl tri (meth) acrylate, propoxylated glyceryl tri (meth) acrylate, tris (2-hydroxyethyl) isocyanurate triacrylate, pentaerythritol tetra (meth) acrylate, ditrimethylolpropane tetra (meth) acrylate And dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) acrylate, and the like.

  Examples of the photopolymerization initiator (S2) include 1-hydroxycyclohexyl phenyl ketone, 2-hydroxy-2-methyl-1-phenylpropan-1-one, 2,2-dimethoxy-1,2-diphenylethane- Examples include 1-one, 2,4,6-trimethylbenzoyldiphenylphosphine oxide, and bis (2,4,6-trimethylbenzoyl) -phenylphosphine oxide. Among these, the irradiation device for curing the photocurable resin composition and the curability of the photocurable resin composition can be arbitrarily selected. In the present invention, the amount of the photopolymerization initiator (S2) contained in the photocurable resin composition is based on the total amount of the photocurable resin composition from the viewpoint of curability and cost of the photocurable resin composition (100 mass). %) Is preferably included in an amount of 0.5% by mass or more and 10.0% by mass or less.

  These photocurable prepolymer (P2), reactive diluent monomer (M2) and photopolymerization initiator (S2) can be used alone or in combination of two or more.

  Specifically, refraction of polymerizable components (specifically, photocurable prepolymer (P2) and reactive dilution monomer (M2)) composed of urethane acrylate, epoxy acrylate, tripropylene glycol diacrylate and methoxytriethylene glycol acrylate. The ratio, viscosity, or influence on the performance of the optical function layer 12 is taken into consideration and used.

  Moreover, you may add a silicone, an antifoamer, a leveling agent, a solvent, etc. to a light absorption part structure composition as an additive as needed.

  The light absorbing particles 16, 16,... Are included in the light absorbing portion constituting composition, and act to absorb stray light and external light when the light absorbing portions 14, 14,.

  As the light-absorbing particles 16, 16,..., Light-absorbing colored particles such as carbon black are preferably used. However, the present invention is not limited to these, and a specific wavelength is selectively selected according to the characteristics of the image light. Absorbing colored particles may be used. Specific examples include organic fine particles colored with metal salts such as carbon black, graphite, and black iron oxide, dyes, pigments, colored glass beads, and the like. In particular, colored organic fine particles are preferably used from the viewpoints of cost, quality, availability, and the like. More specifically, acrylic cross-linked fine particles containing carbon black, urethane cross-linked fine particles containing carbon black, and the like are preferably used. Such colored particles are usually contained in the light absorbing part constituting composition in a range of 3% by mass to 30% by mass. The average particle diameter of the colored particles is preferably 1.0 μm or more and 20 μm or less. When forming the light absorbing portions 14, 14,..., A light absorbing portion constituting composition 46 containing colored particles as shown in FIG. 10 (a diagram schematically showing an apparatus for manufacturing the light absorbing portion). Are filled in the grooves between the light transmitting portions 13, 13,..., And the excess light absorbing portion constituting composition 46 is scraped off using the doctor blade 47. At this time, by using colored particles having an average particle diameter of 1.0 μm or more, it is possible to prevent the colored particles from easily passing through the gap between the doctor blade 47 and the light transmitting portions 13, 13,. The colored particles can be prevented from remaining on the portions 13, 13,.

  Also, depending on the material constituting the light transmission part, the surface of the light absorption part may be filled on the same plane (smooth) with respect to the surface of the light transmission part, or may be filled in a concave shape. is there.

  The means for absorbing light is not limited to the method using light absorbing particles as in this embodiment. Other examples include coloring the entire light absorbing portion with a pigment or dye.

  The light absorbing portions 14, 14,... Can be formed using the above-described light absorbing portion constituting composition as described in detail later.

(Light diffusion layer 20)
The light diffusion layer 20 is a layer that isotropically diffuses light incident from the image light source side and emits the light to the viewer side. Specifically, the light diffusion layer 20 includes a base portion made of a transparent resin and a diffusion component dispersed in the base portion. The light diffusing layer 20 has a function of diffusing light isotropically, for example, due to a difference in refractive index between the base portion and the diffusing component, or due to the reflectivity of the diffusing component itself. Is expressed. However, in the present invention, the light diffusion layer 20 is not limited to a layer that diffuses light isotropically, and may be a layer that diffuses light anisotropically according to the use of a transmissive curved screen. For example, light can be anisotropically diffused by adjusting the distribution of the diffusion component in the base portion and the shape of the diffusion component. Due to such light diffusing ability of the light diffusing layer 20, the image light transmitted through the optical functional layer 12 is diffused, and the observer observes the image within the range of the viewing angle corresponding to the light diffusing ability of the light diffusing layer 20. can do.

  Examples of the transparent resin constituting the base portion of the light diffusion layer 20 include methyl methacrylate / butadiene / styrene copolymer (MBS resin), methyl methacrylate / styrene copolymer (MS resin), acrylic resin, and polycarbonate resin. Can be mentioned.

  Moreover, as what comprises the diffusion component of the light-diffusion layer 20, organic fillers, such as a plastic bead, are suitable, and a thing with especially high transparency is preferable. Examples of the plastic beads include melamine beads, acrylic beads, acrylic-styrene beads, polycarbonate beads, polyethylene beads, polystyrene beads, and vinyl chloride beads. Among these, acrylic beads are preferable. Alternatively, the diffusion component may be a bubble.

  The thickness of the light diffusion layer 20 is preferably 0.1 mm or more and 2 mm or less, and more preferably 0.2 mm or more and 1.5 mm or less. If the thickness of the light diffusion layer 20 is less than 0.1 mm, the light diffusion ability of the light diffusion layer 20 may be insufficient. On the other hand, if the thickness of the light diffusion layer 20 exceeds 2 mm, the resolution of the image displayed on the viewer side of the screen 10 is deteriorated and the image may be blurred.

(Hard coat layer 21)
The hard coat layer 21 is disposed on the most observer side of the screen 10 and constitutes an image display surface of the screen 10. Therefore, the hard coat layer 21 is given resistance to scratches caused by contact with the outside. Such a hard coat layer 21 can be formed, for example, by curing an ionizing radiation curable resin. Specific examples of the ionizing radiation curable resin include acrylic urethane ionizing radiation curable resins.

  Further, since the hard coat layer 21 constitutes the image display surface of the screen 10, it preferably has an antiglare function. According to the hard coat layer 21 having the antiglare function, reflection of external light on the display surface of the screen 10 and reflection of an external image are prevented, and the visibility of the image displayed on the screen 10 display surface is improved. Can do.

(Other layers)
The layers described so far are fixed to each other by fusing or via an adhesive layer. The material of the pressure-sensitive adhesive used for the pressure-sensitive adhesive layer is not particularly limited as long as it transmits light and has appropriate adhesiveness. Examples thereof include an acrylic pressure-sensitive adhesive. The adhesive force is, for example, about several N / 25 mm to 20 N / 25 mm.

  In addition, although illustrated about the form with which the laminated body 31 is equipped with the hard-coat layer 21, the light-diffusion layer 20, the optical function layer 12, and the 1st base material layer 11 in FIG. 2, manufacture of the transmission type curved screen of this invention The laminate of the transmissive curved screen manufactured by the method does not necessarily require all these layers. Further, other layers may be provided. As a layer constituting the laminate, a layer provided in a conventional transmission screen can be appropriately provided. For example, there are layers that can diffuse or collect light by arranging a plurality of transparent spheres and lenses on a transparent substrate.

<Method for manufacturing transmissive curved screen>
The method of manufacturing a transmissive curved screen according to the present invention includes a laminated body having a light diffusion layer capable of diffusing and emitting light incident from an image light source to the viewer side, and a base formed on the image light source side of the laminated body. This is a method of manufacturing a transmissive curved screen that is bent so as to form a three-dimensional curved surface, including a material layer.

  FIG. 8 is a flowchart showing the steps of the method for manufacturing a transmissive curved screen according to the present invention. As shown in FIG. 8, the method of manufacturing a transmissive curved screen includes a laminate production step S1 (hereinafter sometimes simply referred to as “step S1”) for producing a laminate in a flat plate shape, and a step S1. Is preformed in step S2 using a preforming step S2 (hereinafter sometimes simply referred to as “step S2”), in which a flat laminate produced in step 2 is preformed. An injection molding step S3 (hereinafter, simply referred to as “step S3”) is to form a base material layer on the image light source side surface of the laminated body and bend the laminated body and the base material layer to form a three-dimensional curved surface. There is a case.) Taking the case of manufacturing the above-described screen 10 as an example, a method for manufacturing a transmissive curved screen according to the present invention will be described below.

(Process S1)
Step S1 is a step in which the stacked body 31 is formed in a flat plate shape.

  In order to produce the laminated body 31, the diffusion film which comprises the light-diffusion layer 20 is produced first. Examples of the method for producing the diffusion film include a method in which the thermoplastic resin in which the diffusion component is dispersed is formed into a plate shape by extrusion molding.

  Next, the hard coat layer 21 is applied to one surface side of the diffusion film. In order to provide the hard coat layer 21 on one surface side of the diffusion film, there is a method in which the resin constituting the hard coat layer 21 described above is continuously supplied to the one surface side of the diffusion film, and molding is performed. It is done. At this time, when the hard coat layer 21 is provided with the above-described antiglare function, it may be formed by using a mold roll whose surface is a matte surface.

  However, if the laminated body 31 including the hard coat layer 21 is bent as described later after the hard coat layer 21 is cured, the hard coat layer 21 may be cracked. This is because if the resin constituting the hard coat layer 21 is completely cured, the hard coat layer 21 becomes difficult to extend and cannot follow bending.

  Therefore, the following method can be illustrated as a preferable method of providing the hard coat layer 21 on one surface side of the light diffusion layer 20. In the first method, in step S 1, the resin constituting the hard coat layer 21 is not completely cured and the process proceeds to the next step. The hard coat layer 21 is bent at the same time as the laminate 31 is bent or after the laminate 31 is bent. Is a method of curing. The second method is a method of transferring the hard coat layer 21 in step S3 as will be described later. In the third method, after step S3, the resin constituting the hard coat layer 21 is applied to the surface of the light diffusion layer 20 by spray coating, spin coating, dip coating, or the like, and the resin is cured. Is the method.

  On the other hand, the optical function layer 12 is prepared separately from the light diffusion layer 20 and the hard coat layer 21. Hereinafter, the manufacturing method of the optical function layer 12 is demonstrated. FIG. 9 is a cross-sectional view schematically showing a part of the process for an example of the method for manufacturing the optical functional layer 12. FIG. 10 is a perspective view schematically showing another process in the example of the method for manufacturing the optical functional layer 12.

  When producing the optical functional layer 12, as shown in FIG. 9, on the base material 11 ′ that becomes the first base material layer 11 or includes the layer that becomes the first base material layer 11, the light transmitting portion 13, 13 are formed. In order to form the light transmitting portions 13, 13,..., First, a die roll 42 having grooves having a shape corresponding to the shape of the light transmitting portions 13, 13,. Next, the base material 11 ′ is fed between the mold roll 42 and the nip roll 41. The arrow x1 shown in FIG. 9 is the direction in which the substrate 11 'is fed. In accordance with the feeding of the base material 11 ′, the droplets of the light transmitting portion constituting composition 40 are continuously supplied from the supply device 45 between the mold roll 42 and the base material 11 ′. When the light transmitting portion constituting composition 40 is supplied from the supply device 45 onto the base material 11 ′, a bank in which the light transmitting portion constituting composition 40 is accumulated is formed between the mold roll 42 and the base material 11 ′. So that In this bank, the light transmitting portion constituting composition 40 spreads in the width direction of the base material 11 ′.

  The light transmitting portion constituting composition 40 supplied between the mold roll 42 and the base material 11 ′ as described above is formed by the pressing force between the mold roll 42 and the nip roll 41. It is filled between the rolls 42. Then, the light transmission part 13, 40, etc. can be formed by irradiating light to the light transmission part structural composition 40 with the light irradiation apparatus 44, and hardening a light transmission part structural composition. After the light transmitting portions 13, 13,... Are formed, the sheet on which the light transmitting portions 13, 13,. Torn off.

  Next, light absorbing portions 14, 14,... Are formed between the light transmitting portions 13, 13,... Of the sheet obtained through the process shown in FIG. Specifically, the light absorbing portion constituting composition 46 is supplied onto the light transmitting portions 13, 13,..., And the light absorbing portion constituting composition 46 is grooved between the light transmitting portions 13, 13,. While filling 13a, 13a,..., The excess light absorbing portion constituent composition 46 is scraped off, and the light absorbing portion constituent composition 46 remaining in the grooves 13a, 13a,... Between the light transmitting portions 13, 13,. Can be formed by irradiating and curing the light. In this way, the optical functional layer 12 is formed on the first base material layer 11. The arrow x2 shown in FIG. 10 is the sheet feeding direction obtained through the process shown in FIG.

  In the step shown in FIG. 10, the elastic modulus of the light transmitting portions 13, 13,... Is preferably 10 MPa or more and less than 2000 MPa. When the elastic modulus of the light transmitting portions 13, 13,... Is 2000 MPa or more, it becomes hard, causing defects such as cracks and chipping, and when forming the light absorbing portions 14, 14,. There is a possibility that an appearance defect may occur on the surface of the functional layer 12 or the transmittance of the optical functional layer 12 may be reduced. That is, when the light transmitting parts 13, 13,... Are too hard, when the doctor blade 47 scrapes off the surplus portion of the light absorbing part constituting composition 46 supplied onto the light transmitting parts 13, 13,. Are not deformed even if they are pressed against the light transmitting portions 13, 13,..., And therefore there is a possibility that the excess light absorbing portion constituting composition 46 cannot be scraped off. When the elastic modulus of the light transmitting portions 13, 13,... Is in the above range, when the doctor blade 47 is pressed, the excess light absorbing portion constituting composition 46 is scraped off due to the deformation of the light transmitting portions 13, 13,. Defects can be eliminated, and appearance defects on the surface of the optical function layer 12 can be prevented, and the transmittance of the optical function layer 12 can be prevented from decreasing. If the elastic modulus of the light transmitting parts 13, 13,... Is 10 MPa or less, the light transmitting parts 13, 13,... Are too soft, and therefore the light transmitting parts 13, 13,. There is a risk that it will be difficult to release from the roll 42.

  After producing the light diffusion layer 20 and the hard coat layer 21 and the optical functional layer 12 formed on the first base material layer 11 as described above, these are cut to an appropriate size and laminated. Thereby, the flat laminated body 31 can be produced. At this time, the light diffusing layer 20 and the optical function layer 12 are bonded via the pressure-sensitive adhesive layer.

(Preliminary molding step S2)
Step S2 is a step of preforming the flat laminated body produced in step S1. In step 2, it is not necessary to deform the laminate 31 to a final three-dimensional curved surface. In the subsequent step S3, the screen 10 including the laminated body 31 is finally formed into a three-dimensional curved surface by heating (for example, 200 ° C. or more and 250 ° C. or less) and pressurization (for example, 100 kg / cm ² or more and 1500 kg / cm ² or less). This is because it deforms to

  Step S2 will be described with reference to FIGS. 11 and 12 are cross-sectional views schematically showing an example of step S2. As will be described below, the step S2 is preferably a step in which the laminated body 31 is heated to bring the laminated body 31 into vacuum contact and / or pressure contact with a mold capable of obtaining a desired shape. Moreover, you may heat the laminated body 31 and make the laminated body 31 contact | adhere to a metal mold | die using a press member. The temperature at which the laminated body 31 is heated is not less than the glass transition temperature Tg (the glass transition temperature of the layer having the highest glass transition temperature among the layers constituting the laminated body 31), for example, 120 ° C. or higher and 180 ° C. or lower. preferable.

  FIG. 11 illustrates a case where a female mold 50 having a bowl-shaped recess 55 and a flat portion 52 surrounding the periphery is used. When preforming the laminate 31 with the mold 50, first, the laminate 31 is placed on the mold 50 as shown in FIG. At this time, the surface on which the Fresnel lens layer 32 is formed in step S3 is set to the upper side (the side opposite to the mold 50). Thereafter, as shown in FIG. 11B, the flat portion 52 of the mold 50 and the laminate 31 are brought into contact with each other. Then, as shown in FIG.11 (c), by applying an air pressure from the top of the laminated body 31, and / or evacuating from the hole 51,51, ... provided in the metal mold | die 50, the laminated body 31 is shown. And mold 50 are brought into close contact with each other. In this way, the laminate 31 can be preformed.

  FIG. 12 illustrates a case where a male mold 60 having a convex portion 65 having a shape corresponding to the concave portion 55 of the mold 50 shown in FIG. 11 and a flat portion 62 surrounding the periphery thereof is used. When the laminated body 31 is preformed by the mold 60, first, the laminated body 31 is placed on the mold 60 as shown in FIG. At this time, the surface on which the Fresnel lens layer 32 is formed in step S3 is set to the lower side (the mold 60 side). Then, as shown in FIG.12 (b), the top part 64 of the convex part 65 and the laminated body 31 are made to contact. Then, as shown in FIG.12 (c), by applying an air pressure from the top of the laminated body 31, and / or evacuating from the hole 61, 61, ... provided in the metal mold | die 60, the laminated body 31 is shown. And mold 60 are brought into close contact with each other. In this way, the laminate 31 can be preformed.

  When using a female mold as shown in FIG. 11 and when using a male mold as shown in FIG. 12, a case where a male mold is used as described below. Is preferred.

  When the mold 50 is used, the holes 51, 51,... Are provided in the flat portion 52 and the bottom portion 54 of the recess 55 from the viewpoint of efficiently performing vacuuming. Further, as described above, when the stacked body 31 and the mold 50 are brought into close contact with each other, the stacked body 31 is first subjected to pressure after contacting the flat portion 52. At this time, the end portion of the concave portion 55, that is, the portion of the stacked body 31 that is in contact with the boundary 53 between the concave portion 55 and the flat portion 52 is hardly deformed. On the other hand, the portion of the laminate 31 that is in close contact with the bottom 54 is most easily deformed and becomes thinner. The portion of the laminate 31 that is in close contact with the bottom portion 54 is a portion that becomes the center of the screen 10 and is preferably less deformed. This is because if the portion becomes thinner, the brightness and viewing angle of the image may be greatly affected.

  On the other hand, when the mold 60 is used, the holes 61, 61,... Are provided in the flat portion 62 from the viewpoint of efficiently performing vacuuming. Further, as described above, when the laminated body 31 and the mold 60 are brought into close contact with each other, the laminated body 31 is first subjected to pressure after contacting the top portion 64. At this time, the portion of the stacked body 31 that is in contact with the top 64 is difficult to deform. As described above, it is preferable that the portion is less deformed. Thus, the pre-molding using the male mold is preferable because the central portion of the screen 10 can be suppressed from being thinner than the other portions.

  In the description of the step S2 so far, the method of forming the laminate 31 by heating the laminate 31 and performing vacuum adhesion, pressure adhesion, or vacuum / pressure forming has been described. However, the present invention is not limited to such a form. . Step S2 may be a step of heating the laminated body 31 and molding the laminated body 31 by press molding, for example.

  In the description of the step S2 so far, the description has been made with reference to the sectional view of the mold. However, when the mold is viewed three-dimensionally, it is preferable to use a mold as described below.

  FIG. 15A is a perspective view of the mold 150. In FIG. 15A, the hatched portion is a place where a portion of the laminated body 31 that is finally used for the transmissive curved screen 10 is arranged when pre-molding. FIG. 15B is a cross section taken along line XVb-XVb shown in FIG. In the mold 150 shown in FIG. 15, a recess 151 is formed in accordance with a portion of the laminated body 31 that is finally used for the transmissive curved screen 10. Therefore, as shown in FIG. 15B, there is no step in the longitudinal direction of the recess 151, but as shown in FIG. 15C, the flat portion 152 and the recess are formed in the short direction of the recess 151. Steps 153 and 153 are formed between the first and second portions 151. When there is such a step, when the laminate 31 is preformed, the laminate 31 is stretched more than other portions at the step portion, so that the laminate 31 is likely to crack. Therefore, it is preferable to use the mold 160 shown in FIG. 16 or the mold 170 shown in FIG. 17 as a mold for preventing the occurrence of such cracks.

  FIG. 16A is a perspective view of the mold 160. In FIG. 16A, the hatched portion is a place where a portion of the laminated body 31 that is finally used for the transmissive curved surface screen 10 is disposed when molding. FIG. 16B is a cross section taken along line XVIb-XVIb shown in FIG. In FIG. 16B, L3 indicates the width of the portion of the laminate 31 that is finally used for the transmissive curved screen when pre-molding. L4 indicates the width of the portion between the portions indicated by L3 and L3, that is, the portion that is not finally used in the transmissive curved screen 10 and is discarded. FIG. 16C is a cross section taken along line XVIc-XVIc shown in FIG. In FIG. 16C, L5 indicates the width of the portion of the laminated body 10 that is finally used for the transmissive curved screen 10 when preforming. L6 indicates the width of the portion between the portions indicated by L5 and L5, that is, the width of the portion that is not finally used in the transmissive curved screen 10 and is discarded.

  The mold 160 includes a molding part 161 formed of an elliptical or circular recess in plan view, and the molding part 161 is used for preliminary molding of the laminate 31. By forming the molding portion 161 with a concave portion that is oval or circular in plan view, a step between the molding portion 161 and the flat portion 162 can be eliminated. That is, in any cross-sectional view of the mold 160 in the thickness direction, the molded part 161 is formed by a single curve having no corners, and the molded part 161 and the flat part 162 form an obtuse angle. Therefore, the use of the mold 160 can prevent the occurrence of cracks as described above when the laminate 31 is molded. In addition, the mold 160 has a plurality of molding parts 161, and multi-faceting is possible by cutting the laminate 31 into an appropriate size after the step S11. The number of molding parts 161 provided in the mold 160 is not particularly limited. The mold 160 is a so-called female mold in which the molding portion 161 is formed of a concave portion. However, even if a so-called male die having a convex portion having a shape corresponding to the molding portion 161 as a molding portion is used, the laminate 31 is similarly used. It is possible to prevent cracks from occurring.

  Thus, from the viewpoint of preventing cracks from occurring in the laminate 31 in the step S12, it is preferable to use a mold provided with a molding part composed of an elliptical or circular convex part or a concave part in plan view.

  However, since the screen is usually rectangular in a plan view, in a mold such as the mold 160, the laminate 31 is wasted. That is, as shown in FIG. 16C, it is possible to minimize the useless portion L6 on the longitudinal side of the transmissive curved screen, but the transmissive curved screen is rectangular in plan view. For this reason, as shown in FIG. 16B, the useless portion L4 increases on the side of the transmissive curved screen 10 in the short direction. From the viewpoint of reducing such waste, it is preferable to use a mold such as the mold 170 shown in FIG.

  FIG. 17A is a perspective view of the mold 170. In FIG. 17A, a hatched portion is a place where a portion of the laminated body 31 that is finally used for the transmissive curved screen 10 is disposed during molding. FIG. 17B is a cross section taken along line XVIIb-XVIIb shown in FIG. In FIG. 17B, L7 indicates the width of the portion of the laminated body 31 that is finally used for the transmissive curved screen 10 during the preliminary molding. L8 indicates the width of the portion between the portions indicated by L7 and L7, that is, the portion that is not used in the transmissive curved screen 10 and is discarded.

  The mold 170 includes a molding part 171 formed of an elliptical or circular concave part in plan view, and the molding part 171 is used for preliminary molding of the laminate 31. The mold 170 has at least one row in which a plurality of molding portions 171 are arranged (in the form shown in FIG. 17, two rows are provided), and the molding portions 171 adjacent in the row in a plan view are It is formed so that a part of each other overlaps. That is, the half of the length L9 of the line segment connecting the center P of one molding part 171 and the center P of the other molding part 171 adjacent in the row is the center of the molding part 171 located at the end most in the row. It is shorter than the distance L10 from P to the end on the side where the other molding part 171 does not exist. The center P means the deepest position of the molding part 171.

  In this way, by providing the molding part 171 so that the direction corresponding to the short direction of the transmissive curved screen is shortened, as shown in FIG. 17B, the wasted portion L8 can be reduced. it can. The number of molding parts 171 provided in the mold 170 is not particularly limited. The mold 170 is a so-called female mold in which the molding portion 171 is formed of a concave portion. However, even if a so-called male die having a convex portion having a shape corresponding to the molding portion 171 as a molding portion is used, the laminate 31 is similarly used. It is possible to prevent the occurrence of cracks and reduce the number of wasted portions of the laminate 31.

  The depth (in the case of using a female type) or height (in the case of using a male type) of the mold used in step S12 can be appropriately changed according to the use of the transmissive curved screen provided with the laminate 31.

  As described above, after the laminated body 31 is preformed in step S2, the laminated body 31 is appropriately cut into an appropriate shape, and then the process proceeds to step S3.

(Injection molding process S3)
In step S3, the laminate 31 preformed in step S2 is held in an injection mold 70 having grooves 73, 73,... Corresponding to the Fresnel lens 24, and one surface side of the laminate 31 is held. In this step, the Fresnel lens layer 32 is formed. Step S3 will be described with reference to FIG. FIG. 13 is a cross-sectional view schematically showing an example of step S3.

An injection mold 70 shown in FIG. 13 has a female mold 71 and a male mold 72, and the mold 72 has grooves 73 and 73 having a shape corresponding to the unit lens of the Fresnel lens 24. ,…have. First, the laminate 31 is held between the mold 71 and the mold 72. Next, the resin 75 constituting the Fresnel lens layer 32 (the base 23 and the Fresnel lens 24) is melted and injected from a sprue 74 provided in the male mold 72. Then, the resin 75 is heated (for example, 200 ° C. or more and 250 ° C. or less) and pressurized (for example, 100 kg / cm ² or more and 1500 kg / cm ² or less) while being injected into the mold 70. Thereafter, the resin 75 in the mold 70 is cooled. Through this process, the Fresnel lens layer 32 in which the base portion 23 and the Fresnel lens 24 are integrated is formed on one surface side of the laminate 31, and the screen 10 forms a final three-dimensional curved surface. Can be bent. Although not shown, the injection mold 70 is provided with several holes, and the temperature can be controlled with hot water, oil, a heater, or the like. Further, FIG. 13 shows that the opening 74 a of the sprue 74 is provided at a position substantially at the center of the laminated body 31, but actually, the opening 74 a of the sprue 74 is effective for the laminated body 31. It is preferable to provide a region other than the region (the region to which the image light is irradiated when incorporated in the display device). That is, a side gate or the like is preferable. This is because the unit lens 25 is not formed at the position where the opening 74a of the sprue 74 is provided.

  As described above, the hard coat layer 21 can also be formed in step S3. In this case, a sheet in which the resin constituting the hard coat layer 21 is applied on the base film is disposed between the laminate 31 (not including the hard coat layer 21) and the mold 71. As the base film, a film made of PET, polycarbonate resin or the like can be used. The sheet is disposed so that the base film is on the mold 71 side and the resin constituting the hard coat layer 21 is on the laminate 31 side. Thereafter, the hard coat layer 21 is transferred to the laminate 31 by the heat of the resin 75 by injecting and injecting the resin 75 as described above.

  So far, the manufacturing method of the transmissive curved screen of the present invention has been described by taking the screen 10 as an example, but the shape of the transmissive curved screen that can be manufactured by the present invention is not limited to the shape of the screen 10. For example, when a Fresnel lens is unnecessary, an injection mold that forms a smooth curved surface in step S3 may be used. In addition, by changing the shape of the mold, a transmissive curved screen can be manufactured so as to form various three-dimensional curved surfaces. Further, the shape when the transmissive curved screen is formed into a flat plate shape is not limited to a rectangle, and can be various shapes.

  Thus, according to the manufacturing method of the transmissive | pervious curved screen of this invention, the transmissive | pervious curved screen improved in the designability by forming so that a three-dimensional curved surface may be made can be manufactured easily. Such a transmissive curved screen with improved design can be suitably used for parts where design is very important, such as automobile dashboards and amusement equipment.

<Display device>
The display device manufacturing method of the present invention includes a transmissive curved screen having a laminate bent to form a three-dimensional curved surface, an image light source that emits image light, a transmissive curved screen, and an image light source. And a housing for housing the video display device.

  Taking the display device 1 shown in FIG. 3 as an example, a method for manufacturing the display device of the present invention will be described. The transmissive curved screen 10 can be manufactured as described above. The display device 1 can be manufactured by arranging the image light source 3 and the like in the housing 2 and then supporting the transmissive curved screen 10 in the opening of the housing 2. As the housing 2 and the image light source 3, those used in a display device having a conventional transmissive screen can be used without any particular limitation.

  Thus, according to the method for manufacturing a display device of the present invention, it is possible to easily manufacture a display device including a transmissive curved screen with improved design by forming a three-dimensional curved surface. it can.

  Although FIG. 3 illustrates a mode in which the video light L from the video light source 3 is directly applied to the transmissive curved screen 10, the present invention is not limited to such a mode. For example, like the display device 1 ′ shown in FIG. 14, the image light L from the image light source 3 is irradiated onto the mirror 4 provided in the housing 2 ′, and the reflected light L ′ is irradiated with the transmissive curved screen 10. It is good also as a form which irradiates. FIG. 14 illustrates a mode in which the image light L is reflected once by one mirror 4, but the number of mirrors is not particularly limited, and the image light reflected by a plurality of times using a plurality of mirrors is transmissive. The curved screen 10 may be irradiated. If the image light is thus reflected and applied to the transmissive curved screen 10, the depth of the housing can be reduced.

  The present invention has been described above with reference to embodiments that are presently the most practical and preferred. However, the present invention is not limited to the embodiments disclosed in the specification of the present application, and can be appropriately changed without departing from the spirit or idea of the invention that can be read from the claims and the entire specification. It should be understood that a method of manufacturing a transmissive curved screen and a method of manufacturing a display device with such a change are also included in the technical scope of the present invention.

DESCRIPTION OF SYMBOLS 1 Display apparatus 2 Housing | casing 3 Image | video light source 10 Transmission type curved screen 10a Image | video display surface 11 Base material layer 12 Optical function layer 13 Light transmission part 14 Light absorption part 15 Binder 16 Light absorption particle 20 Light diffusion layer 21 Hard coat layer 23 Base 24 Fresnel lens 31 Laminated body 32 Fresnel lens layer 50 Female mold 60 Male mold 70 Injection mold 73 Groove of shape corresponding to Fresnel lens

Claims (9)

A three-dimensional curved surface including a laminate having a light diffusion layer capable of diffusing and emitting light incident from an image light source to the viewer side and a base material layer formed on the image light source side of the laminate A transmissive curved screen that is bent like
A laminate production step of producing the laminate in a flat plate shape;
A preforming step of preforming the flat plate-like laminate produced in the laminate production step;
Using the injection mold, the base material layer is formed on the image light source side surface of the laminate preliminarily molded in the preforming step, and the laminate and the base material layer are formed on the three-dimensional curved surface. Bending the injection molding process,
A method for manufacturing a transmissive curved screen. The base material layer has a Fresnel lens on the observer side,
In the injection molding step, the base material layer is formed on the image light source side surface of the laminate preformed in the preforming step using an injection mold having a groove having a shape corresponding to the Fresnel lens. The method of manufacturing a transmissive curved screen according to claim 1, wherein the laminate and the base material layer are bent so as to form the three-dimensional curved surface. The laminate includes an optical functional layer having a light transmission part arranged in parallel along a sheet surface so as to transmit light, and a light absorption part arranged in parallel so as to be able to absorb light between the light transmission parts. ,
The manufacturing method of the transmissive | pervious curved screen of Claim 1 or 2 with which the said laminated body production process includes the process of forming the said optical function layer.   The pre-molding step is a step of heating the laminated body and molding the laminated body using a mold capable of obtaining a desired shape, and the molding is performed by vacuum adhesion, pressure adhesion, or vacuum pressure molding. The method for producing a transmissive curved screen according to claim 1, wherein the method is performed.   The method for manufacturing a transmissive curved screen according to claim 4, wherein the mold used in the preforming step is a male type.   The said preforming process is a process of press-molding the said laminated body using the metal mold | die which heats the said laminated body and a desired shape is obtained, It is any one of Claims 1-3 characterized by the above-mentioned. A method for producing the transmissive curved screen as described. The mold used in the pre-molding step has a molded part composed of an elliptical or circular convex part or concave part in plan view,
The manufacturing method of the transmission type curved screen in any one of Claims 1-6 which preforms the said laminated body using the said shaping | molding part. The mold used in the preforming step is
It has at least one row in which a plurality of the molding parts are arranged,
The method of manufacturing a transmissive curved screen according to claim 7, wherein the molding parts adjacent in the row are formed so as to partially overlap each other in plan view. An image display apparatus comprising: a transmissive curved screen bent to form a three-dimensional curved surface; an image light source that emits image light; and a housing that supports the transmissive curved screen and accommodates the image light source. A manufacturing method comprising:
The transmissive curved screen has a laminate having a light diffusion layer capable of diffusing and emitting light incident from the video light source toward the viewer, and a base material layer formed on the video light source side of the laminate. Contains
A laminate production step of producing the laminate in a flat plate shape;
A preforming step of preforming the flat plate-like laminate produced in the laminate production step;
Using the injection mold, the base material layer is formed on the image light source side surface of the laminate preliminarily molded in the preforming step, and the laminate and the base material layer are formed on the three-dimensional curved surface. A step of manufacturing the transmissive curved screen, including an injection molding process,
Incorporating the video light source and the transmissive curved screen into the housing;
A method for manufacturing a display device.

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