JP2013152305A - Method for manufacturing reflection screen, reflection screen, and image display system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a reflection screen, by which a reflection screen that can display a bright favorable image with a high contrast can be easily manufactured, and to provide a reflection screen for displaying a favorable image and an image display system including the screen.SOLUTION: A method for manufacturing a reflection screen 10 includes: a first layer formation step of forming a first layer 122 having a concave Fresnel lens pattern in which a plurality of first unit lenses 123 are arranged; a reflection layer formation step of carrying out vapor deposition by arranging a vapor deposition source 60 at an end side corresponding to an optical center of the concave Fresnel lens pattern with respect to a point A as a geometric center of the first layer 122, at a predetermined distance from the first layer 122, to form a reflection layer 13 on at least a part of a lens surface 123a of the first unit lens 123 on a side close to the vapor deposition source 60; and a second layer formation step of applying and curing a resin 124R having a refractive index equal to that of the first layer 122 on the first unit lenses 123 to form a second layer 124 having a convex Fresnel lens pattern.

Description

  The present invention relates to a method for manufacturing a reflective screen that reflects and displays projected video light, and a reflective screen and a video display system including the reflective screen.

In recent years, as a video source for projecting an image on a reflective screen, a short focus type video projection device (projector) that projects a video light at a relatively large incident angle from a close distance to realize a large screen display has been widely used. Yes.
Such a short focus type image projection device can project the reflection screen from above or below at a larger incident angle than the conventional image source, and the distance between the image projection device and the reflection screen in the depth direction. This contributes to the space saving of an image display system using a reflective screen.
In order to satisfactorily display the image light projected by such a short focus type image projection device, the surface of the lens layer having a linear Fresnel lens shape or a circular Fresnel lens shape formed by arranging a plurality of unit lenses is used. Various reflective screens and the like on which a reflective layer is formed have been developed (for example, Patent Documents 1 and 2).

JP-A-8-29875 JP 2008-76523 A

In the reflection screen using the lens layer as described above, a reflection layer is formed on the surface of the lens shape of the unit lens constituting each lens shape, and the projected image light is reflected to display an image.
However, when a reflective layer is formed on a lens-shaped surface, a reflective layer is also formed on a non-lens surface that does not contribute to the reflection of image light, leading to unnecessary reflection of external light such as room illumination light, There has been a problem that the contrast is lowered. Therefore, it is necessary to form the reflective layer only in the portion that contributes to the reflection of the image light.

However, since the unit lens is very fine, it is difficult to accurately form the reflective layer only in the portion that contributes to the reflection of the image light.
In the above-mentioned Patent Documents 1 and 2, there is no disclosure regarding a method for forming such a reflective layer.

  An object of the present invention is to provide a reflection screen manufacturing method capable of easily manufacturing a reflection screen capable of displaying a bright and high-contrast good image, a reflection screen for displaying a good image, and an image display system including the same. That is.

The present invention solves the above problems by the following means. In addition, in order to make an understanding easy, although the code | symbol corresponding to embodiment of this invention is attached | subjected and demonstrated, it is not limited to this.
The invention of claim 1 is a method of manufacturing a reflective screen that reflects image light projected from an image source (LS) and displays it in an observable manner, and a plurality of first unit lenses (123) are arranged on one surface. A first layer forming step of forming a first layer (122) having a concave Fresnel lens shape, and a surface of the first layer on the concave Fresnel lens shape side of the first layer. A predetermined distance from the geometrical center of the surface on the concave Fresnel lens shape side toward the optical center (C) side of the concave Fresnel lens shape with respect to the first layer. A reflective layer forming step of forming a reflective layer (13) on at least a part of the surface on the vapor deposition source side of the first unit lens by arranging the vapor deposition source (60, 60A), and the reflection The first layer is formed on the first unit lens on which the layer is formed. A resin (124R) having the same or substantially the same refractive index is applied and cured to form a second layer (124) having a convex Fresnel lens shape that is the inverse of the concave Fresnel lens shape on the first layer side. And a second layer forming step. A method of manufacturing a reflective screen, comprising:
According to a second aspect of the present invention, in the reflective screen manufacturing method according to the first aspect, in the reflective layer forming step, the vapor deposition source (60, 60A) is an image source in a use state of the reflective screen (10). The reflective screen manufacturing method is characterized in that it is arranged at a predetermined distance with respect to the first layer (122) on the end side which is the LS) side.
According to a third aspect of the present invention, in the reflective screen manufacturing method according to the first or second aspect, in the second layer forming step, the resin (124R) is applied onto the first unit lens (123). Then, a sheet-like member (14, 15, 16) is disposed on the resin layer and cured, and the reflective screen is produced.
According to a fourth aspect of the present invention, in the reflective screen manufacturing method according to any one of the first to third aspects, the resin (124R) used in the second layer forming step is a thermoplastic resin or A method for producing a reflective screen, characterized by being an ionizing radiation curable resin.

A fifth aspect of the invention is a reflective screen manufactured by the method for manufacturing a reflective screen according to any one of the first to fourth aspects, wherein the second layer (124) is the first layer. The reflective layer (13) is located between the first layer and the second layer, and a plurality of the reflective layers (13) are arranged in a strip shape. A reflection screen (10) formed and having an inclination with respect to a screen surface of the reflection screen at least in a part of the arrangement direction.
The invention according to claim 6 is the reflecting screen according to claim 5, wherein the reflecting layer (13) is configured to transmit the image light on the convex Fresnel lens-shaped lens surface (125 a) of the second layer (124). A reflective screen (10) characterized in that it is formed in a reaching region (125a-1).
According to a seventh aspect of the present invention, in the reflective screen according to the fifth or sixth aspect, the convex Fresnel lens shape of the second layer (124) is a circular Fresnel lens shape and is an optical center thereof. The point (C) is the reflecting screen (10) characterized by being located outside the display area of the reflecting screen.
The invention of claim 8 is an image display comprising the reflecting screen (10) according to any one of claims 5 to 7, and an image source (LS) for projecting image light onto the reflecting screen. System (1).

  According to the present invention, it is possible to easily manufacture a reflective screen that can display a good image with high brightness and high contrast. In addition, by manufacturing with the manufacturing method according to the present invention, it is possible to provide a good reflection screen and a video display system in which video light is efficiently reflected and the reduction in contrast due to external light is sufficiently improved.

It is a figure explaining video display system 1 of an embodiment. It is a figure explaining the layer structure of the reflective screen 10 of embodiment. It is a figure explaining the transparent resin layer 12 of embodiment. It is a figure explaining the manufacturing method of reflective screen 10 of an embodiment.

Embodiments of the present invention will be described below with reference to the drawings.
In addition, each figure shown below including FIG. 1 is the figure shown typically, and the magnitude | size and shape of each part are exaggerated suitably for easy understanding.
In addition, the terms “plate”, “sheet”, “film” and the like are used, but these are generally used in the order of thickness, “plate”, “sheet”, “film”. I am using it. However, such proper use has no technical meaning and can be replaced as appropriate.
Furthermore, numerical values such as dimensions and material names of each member described in the present specification are examples of the embodiment, and the present invention is not limited thereto, and may be appropriately selected and used.

(Embodiment)
FIG. 1 is a diagram illustrating a video display system 1 according to the present embodiment. FIG. 1A is a perspective view of the video display system 1, and FIG. 1B is a side view of the video display system 1.
The video display system 1 includes a reflective screen 10, a video source LS, and the like. The video display system 1 according to the present embodiment is a general video display system in which video light L projected from a video source LS is reflected by a reflective screen 10 and a video is displayed on the screen.
The video display system 1 is not limited to this, and may be, for example, a front projection television system that projects video light from the video source LS, or an input on the observation screen of the reflective screen 10, the video source LS, and the reflective screen. An interactive board system including a position detection unit for detecting the position of the unit and a personal computer may be used.

The video source LS is a device that projects the video light L onto the reflective screen 10, and a general-purpose short focus projector or the like can be used. This image source LS is in the center in the left-right direction of the reflection screen 10 when the screen of the reflection screen 10 is viewed from the normal direction (normal direction of the screen surface) in the use state. It is arranged at a position below the screen (display area).
The screen surface refers to a surface that is the planar direction of the reflection screen when viewed as the entire reflection screen.
The video source LS can project the video light L from a position where the distance from the reflective screen 10 in a direction orthogonal to the screen of the reflective screen 10 (thickness direction of the reflective screen 10) is much closer than that of a conventional general-purpose projector. . That is, the image source LS has a shorter projection distance to the reflection screen 10 and a larger incident angle of the image light L with respect to the reflection screen 10 than a conventional general-purpose projector.

The reflection screen 10 is a screen that displays the image by reflecting the image light L projected by the image source LS toward the observer O side. In the use state, the observation screen of the reflection screen 10 has a substantially rectangular shape with the long side direction being the left-right direction of the screen when viewed from the observer O side.
In the following description, unless otherwise specified, the screen vertical direction, screen horizontal direction, and thickness direction are the screen vertical direction (vertical direction) and screen horizontal direction (horizontal direction) when the reflective screen 10 is used. The thickness direction (depth direction) is assumed.

The reflective screen 10 is provided with a flat support plate 50 on the back side thereof via a bonding layer (not shown) made of an adhesive material or the like, and the support plate 50 maintains its flatness. . However, the present invention is not limited thereto, and the reflective screen 10 may be supported by a frame member (not shown) or the like and maintain its flatness.
The reflective screen 10 has a large screen (display area) such as a diagonal of 80 inches or 100 inches. In the reflective screen 10 of the present embodiment, for example, the screen size is a diagonal size of 80 inches (1771 × 996 mm).

FIG. 2 is a diagram illustrating the layer configuration of the reflective screen 10 of the present embodiment.
In FIG. 2, it passes through the point A (see FIGS. 1A and 1B) which is the geometric center of the observation screen (display area) of the reflection screen 10, is parallel to the vertical direction of the screen, and is on the screen surface. A part of a cross section orthogonal (parallel to the thickness direction) is shown enlarged.
The reflective screen 10 includes a surface layer 16, a colored layer 15, a light diffusion layer 14, a reflective layer 13, a transparent resin layer 12, a light absorption layer 11, and the like in order from the image source side (observer side).

Each layer of the reflective screen 10 will be described in order from the back side.
The light absorption layer 11 is a layer having a light absorption function. The light absorption layer 11 is provided on the back side of the reflection screen 10 and covers the entire back side of the reflection screen 10.
The light absorption layer 11 is made of, for example, a thermosetting resin or an ultraviolet curable resin containing a dark paint such as black, a dark pigment or dye such as black and beads having a light absorption function, or a transparent resin. It is formed by applying and curing on the back side of the layer 12. The light absorption layer 11 is colored in a dark color such as black, and a sheet-like member having no light transmission property or low light transmission property is bonded to the back surface of the transparent resin layer 12 by a bonding layer (not shown). May be provided.
This light absorption layer preferably has a thickness having a sufficient light absorption effect of about 30 to 200 μm.

The transparent resin layer 12 is a transparent or substantially transparent light-transmitting layer, and is provided closer to the image source than the light absorption layer 11. The transparent resin layer 12 includes a base material layer 121, a first layer 122, a second layer 124, and a plurality of strip-shaped reflective layers 13.
The base material layer 121 is a layer that becomes a base (base material) of the transparent resin layer 12. As the base material layer 121, a sheet-like member having light permeability can be used. The material of the base material layer 121 includes PET (polyethylene terephthalate) resin, PC (polycarbonate) resin, MS (methyl methacrylate / styrene) resin, MBS (methyl methacrylate / butadiene / styrene) resin, acrylic resin, TAC (trimethyl). Acetyl cellulose) resin, PEN (polyethylene naphthalate) resin, or the like can be used.

The first layer 122 is a layer provided on the video source side of the base material layer 121. The first layer 122 is light transmissive, and a plurality of first unit lenses 123 that are convex toward the image source side are arranged on the image source side surface to form a Fresnel lens shape (so-called concave Fresnel lens shape). ) Is formed.
The second layer 124 is a layer provided on the video source side of the first layer 122. The second layer 124 is light transmissive, and a plurality of second unit lenses 125 that are convex on the back side are arranged on the back side surface, and the Fresnel lens shape (so-called convex Fresnel lens shape) is formed. Is formed.

The first unit lens 123 described above corresponds to the reverse type of the second unit lens 125, and the Fresnel lens shape (concave Fresnel lens shape) formed on the image source side of the first layer 122 is the second layer 124. The shape is the inverse of the Fresnel lens shape (convex Fresnel lens shape) formed on the back side of the lens. The first layer 122 and the second layer 124 are laminated together. In FIG. 2, in order to facilitate understanding, the boundary between the first layer 122 and the second layer 124 where the reflective layer 13 is not formed is shown by a solid line. The form is indistinguishable visually.
In the present embodiment, an example in which a circular Fresnel lens shape is positioned on the back side of the second layer 124 by the second unit lens 125 will be described, but a linear Fresnel lens shape may be used.

FIG. 3 is a diagram illustrating the transparent resin layer 12 of the present embodiment. FIG. 3A shows a state in which the transparent resin layer 12 is observed from the front side on the back side, and the light absorption layer 11 and the like are omitted for easy understanding. FIG. 3B shows an enlarged part of the cross section shown in FIG. 2, and the light diffusion layer 14 and the like are omitted.
A plurality of the first unit lenses 123 and the second unit lenses 125 are arranged concentrically around the point C, and the Fresnel lens shape of the first layer 122 and the second layer is a circular Fresnel lens shape. . In this circular Fresnel lens, a point C which is the optical center (Fresnel center) is outside the area of the screen (display area) of the reflective screen 10 and is positioned below the reflective screen 10.

As shown in FIGS. 2 and 3B, the first unit lens 123 is parallel to the direction orthogonal to the screen surface (thickness direction of the reflective screen 10) and parallel to the arrangement direction of the first unit lenses 123. The cross-sectional shape in a simple cross section is a substantially triangular shape. The first unit lens 123 is convex on the image source side, and includes a lens surface 123a and a non-lens surface 123b facing the lens surface 123a. In the usage state of the reflective screen 10, the first unit lens 123 has the lens surface 123a positioned on the lower side in the vertical direction than the non-lens surface 125b.
As shown in FIG. 2 and FIG. 3B, the second unit lens 125 is parallel to the direction orthogonal to the screen surface (thickness direction of the reflective screen 10) and parallel to the arrangement direction of the second unit lenses 125. The cross-sectional shape in a simple cross section is a substantially triangular shape. The second unit lens 125 is convex on the back side, and includes a lens surface 125a and a non-lens surface 125b facing the lens surface 125a. When the reflective screen 10 is in use, the second unit lens 125 has the lens surface 125a positioned above the non-lens surface 125b in the vertical direction.
The lens surface 123a of the first unit lens 123 corresponds to the lens surface 125a of the second unit lens 125, and the non-lens surface 123b of the first unit lens 123 corresponds to the non-lens surface 125b of the second unit lens 125. Yes.

In the second unit lens 125, as shown in FIG. 3B, the angle formed by the lens surface 125a and the surface parallel to the screen surface is α, and the angle formed by the non-lens surface 125b and the surface parallel to the screen surface. Is β (β> α).
The arrangement pitch of the second unit lenses 125 (the arrangement pitch of the first unit lenses 123) is P, and the lens height of the second unit lenses 125 (between the vertex t1 in the thickness direction of the screen and the second unit lenses 125). H) is a dimension up to the point t2 that becomes the bottom of the valley.

For ease of understanding, in FIG. 2 and the like, the arrangement pitch P and the angles α and β of the second unit lenses 125 are shown to be constant in the arrangement direction of the second unit lenses 125. However, the second unit lenses 125 of the present embodiment are actually constant in the arrangement pitch P and the like, but gradually become larger as the angle α becomes farther from the point C that becomes the Fresnel center in the arrangement direction of the second unit lenses 125. It has become.
However, the present invention is not limited thereto, and the angle α or the like may be constant, or the arrangement pitch P may gradually change along the arrangement direction of the second unit lenses 125, and the video source LS that projects the video light. Can be appropriately changed according to the size of the pixel, the projection angle of the image source LS (the incident angle of the image light on the screen surface of the reflection screen 10), the screen size of the reflection screen 10, the refractive index of each layer, etc. It is.

It is preferable that the first layer 122 and the second layer 124 have the same refractive index because a decrease in contrast caused by stray light caused by unnecessary reflection of external light at the interface can be suppressed. In the present embodiment, the first layer 122 and the second layer 124 will be described by taking the same refractive index as an example. However, the present invention is not limited to this, and the refraction can be regarded as substantially the same refractive index. You may have a rate difference.
The first layer 122 and the second layer 124 may have a refractive index that is relatively high as a resin for optical applications (for example, a refractive index of about 1.55 to 1.60). The resin for use may be relatively low (for example, a refractive index of about 1.45 to 1.50).
When the refractive indexes of the first layer 122 and the second layer 124 are relatively high, the lens height of the first unit lens 123 and the second unit lens 125 can be reduced, and thus manufacturing is facilitated. . Further, when the refractive indexes of the first layer 122 and the second layer 124 are relatively low, the lens heights of the first unit lens 123 and the second unit lens 125 become high, and the non-lens surfaces 123b, The area of 125b is increased, and the proportion of external light that is transmitted between the reflective layers 13 and absorbed by the light absorption layer 11 on the back surface side increases, so that a contrast improvement effect can be expected.

The first layer 122 may be formed of an ultraviolet curable resin such as urethane acrylate or epoxy acrylate, or an ionizing radiation curable resin such as an electron beam curable resin, or may be formed using a thermoplastic resin or the like. Also good.
The second layer 124 may be formed using the same resin material as the first layer 122, or may be formed using a different resin material. The second layer 124 may use an ionizing radiation curable resin such as the ultraviolet curable resin as described above, or a molding resin such as a thermoplastic resin, or an adhesive made of an ultraviolet curable or thermoplastic resin. You may form using.
In the present embodiment, the first layer 122 is formed of an acrylic ultraviolet curable resin, and the second layer 124 is formed of the same acrylic ultraviolet curable resin as the first layer 122. I will give you a description.

The reflective layer 13 is a layer that has a function of reflecting light. The reflective layer 13 has a strip shape, and a plurality of the reflective layers 13 are arranged between the first layer 122 and the second layer 124 described above. Therefore, when only the transparent resin layer 12 is visually recognized, the reflective layer 13 includes a plurality of layers that are inclined with respect to the screen surface in the transparent or substantially transparent resin layer including the first layer 122 and the second layer 124. Visible as a band-like layer.
The reflection layer 13 is provided on the lens surface 125a of the second unit lens 125 in the reflection region 125a-1 that is the region where the image light reaches, and is not on the lens surface 125a that is the region where the image light does not reach. The reflective layer 13 is not formed in the reflective region 125a-2 and the non-lens surface 125b. The reflection area 125a-1 and the non-reflection area 125a-2 of the second unit lens 125 correspond to the reflection area 123a-1 and the non-reflection area 123a-2 of the first unit lens 123, respectively.
The reflective layer 13 is formed by vapor-depositing a metal having high light reflectivity such as aluminum, silver, or nickel, and the film thickness is about 0.1 μm. The reflective layer 13 of this embodiment is an aluminum vapor deposition film.

Returning to FIG. 2, the light diffusion layer 14 is a layer containing a light diffusing material using a light-transmitting resin as a base material. The light diffusion layer 14 is provided on the image source side of the transparent resin layer 12. The light diffusion layer 14 has a function of widening the viewing angle and improving the in-plane uniformity of brightness.
Examples of the resin used as the base material of the light diffusion layer 14 include PET (polyethylene terephthalate) resin, PC (polycarbonate) resin, MS (methyl methacrylate / styrene) resin, MBS (methyl methacrylate / butadiene / styrene) resin, and acrylic resin. Resin, TAC (triacetyl cellulose) resin, PEN (polyethylene naphthalate) resin, or the like can be used. The thickness of the light diffusion layer 14 is, for example, 100 to 200 μm. Further, as the diffusing material, acrylic resin, epoxy resin, silicon-based resin particles, inorganic particles, and the like, and those having an average particle diameter of about 1 to 50 μm can be used.

The colored layer 15 is a layer colored with a dye or pigment such as gray or black for obtaining a predetermined transmittance. The colored layer 15 has a function of improving the contrast of the image by absorbing unnecessary external light such as illumination light incident on the reflective screen 10 and reducing the black luminance of the displayed image. The colored layer 15 of the present embodiment is integrally provided on the image source side (observer side) of the light diffusion layer 14.
The colored layer 15 can be formed of a PET resin containing a dye or a pigment, a PC resin, an MS resin, an MBS resin, an acrylic resin, a TAC resin, a PEN resin, or the like. The thickness of the colored layer 15 is, for example, 30 to 3000 μm.

The light diffusion layer 14 and the colored layer 15 of the present embodiment are integrally laminated by coextrusion.
In the present embodiment, as shown in FIG. 2, an example is shown in which the light diffusion layer 14 is on the back side and the colored layer 15 is positioned on the image source side. It is good also as a form which is located in a video source side and the colored layer 15 is located in a back side. In addition to the above example, the reflective screen 10 may not include the colored layer 15, and the light diffusion layer 14 may include a colorant such as a pigment or a dye in addition to the light diffuser.

The surface layer 16 is a layer provided on the image source side (observer side) in the reflective screen 10. In the present embodiment, the surface layer 16 is on the image source side of the colored layer 15 and is provided at a position closest to the image source side.
The surface layer 16 can be provided with one or more appropriate functions such as an antireflection function, an antiglare function, an ultraviolet absorption function, an antifouling function, an antistatic function, a hard coat function, and a touch panel function. .
The surface layer 16 is a layer separate from the colored layer 15 and the light diffusing layer 14 and may be joined to the colored layer 15 by an adhesive material (not shown) or on the image source side surface of the colored layer 15. Alternatively, it may be formed directly by applying a resin having various functions.

  The surface layer 16 of this embodiment has an antiglare function and a hard coat function (scratch resistance function). The surface layer 16 of the present embodiment is formed by, for example, applying an ionizing radiation curable resin (urethane acrylate or the like) having a hard coat function to the surface on the image source side of the colored layer 15 to a thickness of about 10 to 100 μm. The shape (mat shape) can be formed by transferring the surface of the resin film to the surface of the resin film and curing it to form a fine uneven shape on the surface.

Returning to FIG. 2, the state of the image light and the external light incident on the reflection screen 10 of the present embodiment will be described. In order to facilitate understanding, in FIG. 2, the refractive index difference of each layer in the reflection screen 10 and the diffusion action of the light diffusion layer 14 are omitted, and the video light L1 and the external light G1, which travel through the reflection screen 10 G2 is schematically shown.
As shown in FIG. 2, most of the image light L1 projected from the image source LS is incident from below the reflection screen 10, passes through the surface layer 16, the colored layer 15, the light diffusion layer 14, and the like, and is transparent resin. It is incident on the second layer 124 of the layer 12. Then, the image light L1 enters the reflection region 125a-1 on the lens surface 125a of the second unit lens 125, is reflected by the reflection layer 13, and exits from the reflection screen 10 toward the observer O side.
Note that the angle β (see FIG. 3B) is larger than the incident angle of the image light L1 at each point in the vertical direction of the screen of the reflection screen 10, and the image light L1 is projected from below the reflection screen 10. Therefore, the image light L1 does not directly enter the non-lens surface 125b, and the non-lens surface 125b does not affect the reflection of the image light L1.

On the other hand, unnecessary external lights G1 and G2 such as illumination light are mainly incident from above the reflection screen 10 and transmitted through the surface layer 16, the colored layer 15 and the light diffusion layer 14 as shown in FIG. It is incident on the layer 12.
Then, a part of the external light G1 enters the first layer 122 from the non-lens surface 125b (non-lens surface 123b) between the reflective layers 13, passes through the transparent resin layer 12, and enters the light absorption layer 11. And absorbed. Similarly, external light (not shown) incident on the non-reflective region 125a-2 of the lens surface 125a is also incident on the first layer 122, transmitted through the transparent resin layer 12, and incident on the light absorption layer 11. And absorbed.
Further, a part of the external light G2 is reflected by the reflective layer 13 of the lens surface 125a and mainly travels downward of the reflective screen 10, so that it does not reach the observer O side directly, and also when it reaches The amount of light is significantly less than that of the image light L1. Therefore, the reflective screen 10 can suppress a decrease in the contrast of the image due to the external lights G1 and G2.

FIG. 4 is a diagram illustrating a method for manufacturing the reflective screen 10 of the present embodiment.
First, the sheet-like base material layer 121 is prepared. In this embodiment, the base material layer 121 uses a sheet-like member made of PET resin having a thickness of 250 μm.
In this embodiment, as shown in FIG. 4A, one surface of the base material layer 121 is pressed against a mold for shaping a circular Fresnel lens shape filled with an ultraviolet curable resin, and irradiated with ultraviolet rays. After being cured, the first layer 122 is formed by releasing from the mold (first layer forming step).
In the present embodiment, as described above, the method of forming the first layer 122 has been exemplified by using the ultraviolet molding method. However, the first layer 122 may be appropriately selected according to the resin or the like that forms the first layer 122. Well, this is not the case.

Next, the reflective layer 13 is formed by a vapor deposition method.
In the present embodiment, aluminum is used as the vapor deposition metal for forming the reflective layer 13, and the base material layer 121 on which the first layer 122 is formed and the vapor deposition source 60 having the vapor deposition metal are provided in a vacuum container (not shown). Place and vacuum deposit. The vapor deposition source 60 includes a vapor deposition metal and a heating body (filament or the like) (not shown) that heats the vapor deposition metal.
As shown in FIGS. 4B and 4C, the vapor deposition source 60 is located at a position facing the surface side of the first layer 122 on the Fresnel lens shape (concave Fresnel lens shape) side of the reflective screen 10. In a state of use, a predetermined amount with respect to the first layer 122 is provided in the vicinity of the screen end portion on the projection light side of the image light source LS in the use state (the point C side that is the Fresnel center of the Fresnel lens shape of the first layer 122). Arranged at a distance.
The deposited metal is heated and melted by the heating body and evaporates.
The evaporated aluminum collides with and adheres to the first layer 122 as gas molecules. At this time, the evaporated aluminum is likely to hit the lens surface 123 a on the vapor deposition source 60 side of the first unit lens 123. Moreover, since the vapor deposition source 60 is provided on the projection light side of the image light, the evaporated aluminum hits a region (reflection region 123a-1) where the image light reaches the lens surface 123a when the reflection screen 10 is used. On the other hand, it is difficult to hit the area where the image light does not reach (non-reflective area 123a-2) or the non-lens surface 123b.

Thereby, while the reflective layer 13 is efficiently formed in the reflective region 123a-1 by the aluminum evaporated from the vapor deposition source 60, vapor deposition on the non-reflective region 123a-2 and the non-lens surface 123b can be suppressed.
Therefore, according to the present embodiment, it is possible to efficiently form the reflective layer 13 only in the region (the reflective region 123a-1) where the image light reaches the first layer 122 when the reflective screen 10 is used. .

Depending on the screen size or the like of the reflective screen 10, only the vapor deposition source 60 arranged at the position as described above is sufficient to reflect the image light on the left and right end portions of the screen above the reflective screen 10 and the like. In some cases, a deposited film (reflective layer 13) having a thickness (about 0.1 μm) cannot be formed. In such a case, in addition to the vapor deposition source 60, as shown in FIG. 4C, the point A (the Fresnel lens shape side surface geometry of the first layer 122) which is the screen center of the reflective screen 10 is used. Evaporation may be performed by further disposing a deposition source 60A near the lower end of the reflective screen 10 on the image source LS side (point C side serving as the Fresnel center) rather than the image center LS. It is preferable to arrange the vapor deposition sources 60 and 60A at the positions as described above in order to form the reflective layer 13 having a sufficient thickness (about 0.1 μm) for the reflection of the image light in the reflective region 123a-1. . Note that the number of vapor deposition sources is preferably one, but a plurality of vapor deposition sources may be arranged as described above.
The reflective layer 13 formed by the vapor deposition method as described above may be thinner in the arrangement direction of the first unit lenses 123 as the distance from the vapor deposition sources 60 and 60A increases. The thickness may be equal regardless of the position.

  By using the vapor deposition method as described above, as shown in FIG. 4D, the reflection layer 13 is formed in the reflection region 123a-1 that is the region where the image light of the first unit lens 123 reaches, and the image light The reflective layer 13 is not formed in the non-reflective region 123a-2 and the non-lens surface 123b that do not contribute to the reflection of light. Therefore, it is possible to easily pattern the reflective layer 13 in a region where the image light reaches.

Next, as shown in FIG. 4E, a resin 124 </ b> R that forms the second layer 124 is applied onto the first unit lens 123 and the reflective layer 13 of the first layer 122 by using a die 61 or the like. In the present embodiment, the resin 124R is the same ultraviolet curable molding resin as that of the first layer 122, and when applied, the resin 124R is heated and has fluidity. The unevenness of the lens 123 is filled.
And after apply | coating resin 124R, the laminated body which consists of the surface layer 16, the colored layer 15, and the light-diffusion layer 14 integrally molded on the resin 124R is laminated | stacked, and an ultraviolet-ray is irradiated from the laminated body side, resin 124R is cured. As a result, the second layer 124 having a Fresnel lens shape (convex Fresnel lens shape) formed by a plurality of second unit lenses 125 is formed (second layer 124 forming step). Further, the resin 124R is cured, so that the first layer 122 in which the reflective layer 13 is formed via the second layer 124 and the laminate (the light diffusion layer 14, the colored layer 15, and the surface layer 16) are formed. Become one.

In the present embodiment, the light diffusion layer 14 is a layer having a thickness of 150 μm obtained by extruding an MBS resin made of acrylic resin containing particles having an average particle diameter of 10 μm as a diffusion material. The colored layer 15 is a layer having a thickness of 70 μm containing a black pigment. The light diffusion layer 14 and the colored layer 15 are coextruded. Then, an ionizing radiation curable resin having a hard coat function (for example, urethane acrylate) is applied to the surface of the colored layer 15 to a thickness of about 30 μm, and a fine uneven shape (matt shape) is transferred to the surface of the resin film. And so on, to form a fine uneven shape on the surface. Thereby, the surface layer 16 is formed on the colored layer 15.
As described above, since the second layer 124 of this embodiment is an ultraviolet curable resin, it is cured by irradiation with ultraviolet rays. However, when a thermoplastic resin is used, it is cured by cooling. The second layer 124 is not limited to the ultraviolet curable resin as described above, and other ionizing radiation curable resins, thermoplastic resins, or other molding resins may be used. An adhesive or the like may be used.

Next, the light absorbing layer 11 is formed by applying and curing an ink containing a pigment such as black on the surface of the base material layer 121 with a film thickness of about 50 μm.
Through the steps as described above, the reflective screen 10 of the present embodiment is formed as shown in FIG.
In the present embodiment, since the second layer 124 has a circular Fresnel lens shape, the example in which the reflective screen 10 is formed using the sheet-like base material layer 121 or the like has been described. When the first layer 122 has a linear Fresnel lens shape, the reflective screen 10 may be formed by using a web-like base material layer 121 and appropriately providing a cutting step before vapor deposition.
In addition, as long as the curing of the first layer 122 and the second layer 124 is not affected, the order of the steps for forming the light absorption layer 11 may be changed as appropriate.
Further, the surface layer 16 may be formed on the colored layer 15 after the colored layer 15 and the light diffusion layer 14 are integrally laminated on the second layer 124.

It has been difficult to form the reflective layer 13 only in the reflective region 125a-1 (123a-1) by a method such as printing or transfer that has been widely used. However, according to this embodiment described above, it is possible to easily and efficiently form the reflective layer 13 only in the reflective region 125a-1 (123a-1) where the image light reaches.
Therefore, it is possible to easily manufacture a reflective screen that can display a good image with a bright and high contrast and an image display system including the same.

(Deformation)
The present invention is not limited to the embodiment described above, and various modifications and changes are possible, and these are also within the scope of the present invention.
(1) In the present embodiment, an example in which the first layer 122 is made of an ultraviolet curable resin and is integrally formed on one surface of the base material layer 121 by an ultraviolet molding method is not limited thereto. For example, you may form by an extrusion molding method, an injection molding method, etc. with a thermoplastic resin etc.
At this time, if the first layer 122 has sufficient thickness and rigidity, the substrate layer 121 may not be provided. In the case of the extrusion molding method, extrusion molding may be performed in a state where the first layer 122 and the base material layer 121 are integrally laminated. By adopting such a form, mass production is further facilitated and can be provided at low cost.

(2) In the present embodiment, the second layer 124 has a form that does not contain a light diffusing material. However, the present invention is not limited to this. For example, the second layer 124 may have a form that contains a light diffusing material. Good. By adopting such a configuration, the viewing angle can be improved.

(3) In the present embodiment, the resin 124R is applied on the first layer 122, and the laminate (the light diffusion layer 14, the colored layer 15, and the surface layer 16) is disposed thereon and irradiated with ultraviolet rays. Although the example in which the resin 124R is cured is shown, the present invention is not limited to this, and the laminate (light diffusion layer 14, colored layer 15, surface layer) is cured via a bonding layer (not shown) on the resin 124R first. 16) may be laminated.

(4) In the present embodiment, an example in which the reflective screen 10 includes the surface layer 16, the colored layer 15, and the light diffusion layer 14 on the image source side with respect to the transparent resin layer 12 has been described. It is good also as a form provided with a layer. For example, the reflective screen 10 may include a prism layer or a lens layer in which unit prisms or unit lenses are arranged in the vertical direction of the screen or the horizontal direction of the screen, or in order to maintain the flatness of the screen of the reflective screen 10. Further, a highly rigid substrate layer made of glass or resin may be provided.
Moreover, in this embodiment, although the reflective screen 10 showed the example provided with the light-diffusion layer 14 and the colored layer 15, it is good also as a form provided with only not only this but the light-diffusion layer 14. It is good also as a form containing a coloring agent.

(5) In this embodiment, although the surface layer 16 showed the example provided with a hard-coat function, the reflection reduction function of the image light to a ceiling, and an anti-glare function, it is not restricted to this, An antireflection function and ultraviolet absorption Functions, antifouling functions, antistatic functions and the like may be appropriately selected and further provided.
These layers may be provided as a separate layer between the surface layer 16 and the colored layer 15 described above, or may be formed by selecting a resin that forms the surface layer 16 having the above-described function. Good.

(6) In the present embodiment, the second unit lens 125 has an example in which the cross-sectional shape shown in FIG. 2 and the like is a substantially triangular shape. However, the present invention is not limited to this. For example, the non-reflective region 125a-2 portion is a screen. It is good also as the substantially trapezoid shape cut along the surface parallel to a surface.

(7) In the present embodiment, the reflective screen 10 is joined to the support plate 50 provided on the back side thereof via an adhesive material layer (not shown) and the like, and has an example of a substantially flat plate shape. Not limited to this, for example, the support plate 50 may not be provided, and the reflective screen 10 may be bonded to the wall surface or the like via an adhesive layer or the like, or may be fixed to the wall surface with the support plate 50 bonded to the back surface. It is good also as a form etc. which are hung on a wall surface by support members, such as a hook.
In the present embodiment, the reflective screen 10 has an example of a substantially flat plate shape when in use and not in use. However, the present invention is not limited to this. . In such a form, the support plate 50 or the like is not provided, and the back side of the reflective screen 10 is covered with a cloth or resin light-shielding curtain that hardly transmits light, a protective layer that improves scratch resistance, or the like. It is good.

(8) In the present embodiment, the second unit lens 125 has an example in which the lens surface 125a and the non-lens surface 125b are linear in the cross section shown in FIG. 3 and the like. For example, part of the lens surface 125a and the non-lens surface 125b may be curved.
In the present embodiment, the lens surface 125a and the non-lens surface 125b of the second unit lens 125 are both single surfaces. However, the present invention is not limited to this. For example, at least one surface includes a plurality of surfaces. It is good also as a form comprised from these surfaces.
When the second unit lens 125 is configured as described above, the first unit lens 123 is a reverse type of the second unit lens 125.

(9) In the present embodiment, the example in which the surface layer 16 is provided on the most image source side (observer side) of the reflective screen 10 is shown, but not limited thereto, for example, the light diffusion layer 14 is disposed on the image source side, The colored layer 15 may be the back side, the light diffusion layer 14 may be the surface layer, and a fine uneven shape may be formed on the image source side surface during extrusion molding.

(10) In the present embodiment, the video source LS is located below the reflective screen 10 in the vertical direction, and the video light L is projected obliquely from below the reflective screen 10. However, the present invention is not limited to this. For example, the video source LS may be positioned above the reflective screen 10 in the vertical direction, and the video light L may be projected obliquely from above the reflective screen 10.
At this time, the reflective screen 10 has a configuration in which the vertical direction of the transparent resin layer 12 shown in FIG. 2 and the like is reversed, and the point C which is the optical center (Fresnel center) of the circular Fresnel lens is located above the reflective screen 10. do it.

  In addition, although this embodiment and modification can also be used in combination as appropriate, detailed description is abbreviate | omitted. Further, the present invention is not limited to the embodiment described above.

DESCRIPTION OF SYMBOLS 1 Video display system 10 Reflective screen 11 Light absorption layer 12 Transparent resin layer 122 1st layer 123 1st unit lens 124 2nd layer 125 2nd unit lens 13 Reflection layer 14 Light-diffusion layer 15 Colored layer 16 Surface layer

Claims (8)

A method of manufacturing a reflective screen that reflects image light projected from an image source and displays the image light in an observable manner,
A first layer forming step of forming a first layer having a concave Fresnel lens shape in which a plurality of first unit lenses are arranged on one surface;
An optical center side of the concave Fresnel lens shape with respect to a surface of the first layer on the concave Fresnel lens shape side with respect to a geometric center of the surface of the first layer on the concave Fresnel lens shape side; The deposition is performed by disposing an evaporation source at a predetermined distance with respect to the first layer on the end side to be reflected on at least a part of the surface on the evaporation source side of the first unit lens. A reflective layer forming step of forming a layer;
On the first unit lens on which the reflective layer is formed, a resin having a refractive index equal to or substantially equal to that of the first layer is applied and cured, and the concave shape of the concave Fresnel lens is reversed on the first layer side. A second layer forming step of forming a second layer having a convex Fresnel lens shape as a mold;
Providing
A manufacturing method of a reflective screen characterized by the above. In the manufacturing method of the reflective screen of Claim 1,
In the reflective layer forming step, the vapor deposition source is arranged at a predetermined distance from the first layer on an end side which is an image source side in a use state of the reflective screen.
A manufacturing method of a reflective screen characterized by the above. In the manufacturing method of the reflective screen of Claim 1 or Claim 2,
In the second layer forming step, after the resin is applied on the first unit lens, a sheet-like member is disposed on the resin layer and cured,
A manufacturing method of a reflective screen characterized by the above. In the manufacturing method of the reflective screen of any one of Claim 1- Claim 3,
The resin used in the second layer forming step is a thermoplastic resin or an ionizing radiation curable resin;
A manufacturing method of a reflective screen characterized by the above. A reflective screen manufactured by the method for manufacturing a reflective screen according to any one of claims 1 to 4,
The second layer is located closer to the video source than the first layer,
The reflective layer is located between the first layer and the second layer, and is formed by being arranged in a plurality of strips, and at least partly in the arrangement direction is inclined with respect to the screen surface of the reflective screen Having
Reflective screen featuring. The reflective screen according to claim 5.
The reflective layer is formed in a region where the image light reaches on the convex Fresnel lens-shaped lens surface of the second layer;
Reflective screen featuring. The reflective screen according to claim 5 or 6,
The convex Fresnel lens shape of the second layer is a circular Fresnel lens shape, and the optical center point thereof is located outside the display area of the reflective screen;
Reflective screen featuring. A reflective screen according to any one of claims 5 to 7,
An image source for projecting image light onto the reflective screen;
A video display system comprising:

Images