JP2016117233A - Laminate mold release method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminate mold release method capable of suppressing adhesion of a split of a resin to a laminate.SOLUTION: A mold release method of a laminate U is configured to: fill a resin into a molding mold 50; dispose a base material sheet V on the resin and press the sheet for curing the resin; then release the laminate U in which, a lens layer 23 is molded on the base material sheet V from the molding mold 50. The laminate U is released from the molding mold 50 with a conductive cloth 60, in a state of disposing the conductive cloth 60 on the laminate U.SELECTED DRAWING: Figure 5

Description

  The present invention relates to a method for releasing a laminate in which a laminate in which a lens layer is molded on a substrate is released from a molding die.

  Conventionally, reflective screens having various configurations have been developed and used in video display systems. In recent years, short focus type video projection devices (projectors) that project a video light at a relatively large projection angle from a close distance to a reflective screen to realize a large screen display have been widely used. Reflective screens and the like have also been developed for satisfactorily displaying video light projected by a short focus type video projector.

The short focus type image projection apparatus can project image light at a larger projection angle than the conventional image source from above or below the reflection screen, and the distance in the depth direction between the image projection apparatus and the reflection screen. Therefore, it is possible to contribute to space saving of an image display system using a reflective screen (for example, Patent Document 1).
The reflection screen of Patent Document 1 has a lens layer that transmits image light. This lens layer presses a substrate against a molding die that shapes a lens shape filled with resin, After being cured, it is formed on the substrate by releasing from the molding die.

JP 2012-252057 A

At this time, the resin filled in the molding die is used more than the volume of the lens layer in order to properly shape the lens layer in the die. Therefore, in addition to the resin that forms the lens layer, there is an excess resin that is an excess. This excess resin remains on the outer periphery of the lens layer, and is removed from the laminated body after the substrate on which the lens layer is molded (hereinafter referred to as a laminated body) is released from the molding die.
Here, since the base material and the lens layer constituting the laminate are each formed of a material (resin) having low conductivity, static electricity is easily charged. In addition, when the laminate is released from the molding die, the excess resin may be cut off from the lens layer. In this case, the excess resin debris or the uncured portion of the excess resin is caused by static electricity. In some cases, the lens layer is attracted to and adhered to the layer, and the lens layer of the laminate is damaged or soiled.

  The subject of this invention is providing the mold release method of a laminated body which can suppress that the fragment of a resin adheres to a laminated body.

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.
According to the first aspect of the present invention, the molding die (50) is filled with a resin, a base material (V, 24) is placed on the resin and pressed, and then the resin is cured, and then the base In this method, the laminate (U) having the lens layer (23) formed thereon is released from the molding die, and a conductive member (60, 61) is placed on the laminate. It is arrange | positioning, The said laminated body is released from the said metal mold | die with the said electroconductive member, It is a mold release method of the laminated body characterized by the above-mentioned.
The invention of claim 2 is the method for releasing a laminate according to claim 1, wherein the conductive members (60, 61) are grounded. .
Invention of Claim 3 is the mold release method of the laminated body of Claim 1 or Claim 2, The said electroconductive member (60) is an electroconductive cloth, The external dimension seen from the thickness direction is, The layered product release method is characterized in that the layered product (U) is formed approximately equal to the outer dimension.
According to a fourth aspect of the present invention, in the method for releasing a laminate according to the first or second aspect, the conductive member (61) is a conductive string, and a lattice is formed on the laminate (U). It is the mold release method of the laminated body characterized by arranging in a shape.

  ADVANTAGE OF THE INVENTION According to this invention, the mold release method of the laminated body which can suppress that the fragment of resin etc. adhere to a laminated body can be provided.

It is a figure explaining the video display system of an embodiment. It is a figure explaining the layer structure of the reflective screen of embodiment. It is a figure explaining the detail of the lens layer and reflection layer of embodiment. It is a figure explaining the manufacturing method of the reflective screen of an embodiment. It is a figure explaining the detail of the formation process of the lens layer of embodiment. It is a figure which shows the example of arrangement | positioning of the electroconductive string with respect to the laminated body of embodiment. It is a figure which shows the detail of the charge amount measurement of the static electricity which charges the laminated body of an Example and a comparative example.

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, words such as plate and sheet are used, but these are generally used in the order of thickness, plate, sheet, and film in order of increasing thickness. I use it. However, there is no technical meaning in such proper use, so these terms 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.

In this specification, terms that specify shape and geometric conditions, for example, terms such as parallel and orthogonal, are strictly meanings, have similar optical functions, and can be regarded as parallel and orthogonal It also includes a state having an error of.
In this specification, the sheet surface (plate surface, film surface) is the planar direction of the sheet (plate, film) when viewed as the entire sheet (plate, film) in each sheet (plate, film). It is assumed that the surface to be

(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 unit 10 including a reflective screen 20, a video source LS, and the like. In the video display system 1 of the present embodiment, the reflective screen 20 reflects the video light L projected from the video source LS, and displays the video on the screen.
The video display system 1 can be used as, for example, a front projection television system that projects video light L from a video source LS.

The video source LS is a video light projection device that projects the video light L onto the reflection screen 20. The video source LS of this embodiment is a general-purpose short focus projector. When the image source LS is in use and the screen of the reflection screen 20 is viewed from the normal direction (normal direction of the screen surface), the image source LS is the center in the horizontal direction of the screen of the reflection screen 20 and the image of the reflection screen 20 It is arranged at a position below the (display area).
The screen surface refers to a surface that is the planar direction of the reflective screen 20 when viewed as the entire reflective screen 20.
The video source LS can project the video light L from a position where the distance from the reflective screen 20 in a direction orthogonal to the screen of the reflective screen 20 (thickness direction of the reflective screen 20) 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 20 and a larger incident angle of the image light L with respect to the screen surface of the reflection screen 20 than a conventional general-purpose projector.

The reflection screen 20 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 20 has a substantially rectangular shape with the long side direction being the horizontal direction of the screen when viewed from the observer O side.
In the following description, the screen vertical direction, the screen horizontal direction, and the thickness direction are the screen vertical direction (vertical direction), the screen horizontal direction (horizontal direction), and thickness when the reflective screen 20 is used unless otherwise specified. The direction (depth direction) is assumed.
The reflective screen 20 has a large screen (display area) having a diagonal size of 100 inches or 120 inches, for example.

  The video display system 1 of the present embodiment includes a video source LS that is a short focus type projector, and a reflective screen 20 that displays video by reflecting video light projected from the video source LS. However, the present invention is not limited to this, and the image source LS is a conventional general-purpose projector having a long projection distance and a small image light projection angle (that is, an incident angle of the image light on the screen), and the reflection screen 20 is such a projector. It may correspond to the video source LS.

  As shown in FIG. 1, the reflective screen unit 10 includes a reflective screen 20, a flat support plate 30 disposed on the back side thereof, and a bonding layer 40. The reflection screen 20 and the support plate 30 are integrally bonded via a bonding layer 40.

The support plate 30 is not particularly limited as long as it is a member having high rigidity. For example, a metal plate material such as aluminum or a resin plate material such as acrylic resin is preferably used. . In addition, a metal plate material (so-called honeycomb panel) that reduces the weight of the entire plate material by providing a honeycomb structure formed of a thin plate of aluminum or the like on the front and back surfaces and a thin plate of aluminum or the like as an inner core material. Etc. may be used. Moreover, it is preferable that the support plate 30 is a member which does not have a light transmittance from a viewpoint of preventing the reflection of external light, the contrast fall by external light, etc.
The thickness of the support plate 30 is preferably 0.2 to 10.0 mm, more preferably 1.0 to 3.0 mm. If the thickness is less than 0.2 mm, sufficient rigidity to support the flatness is insufficient, and if the thickness is more than 10.0 mm, the weight of the support plate 30 becomes heavy.
In many cases, the reflective screen 20 is thin and does not have sufficient rigidity to maintain flatness by itself. For this reason, the reflection screen 20 maintains the flatness of the screen by being integrally joined to the support plate 30.

  The bonding layer 40 is a layer having a function of bonding the reflective screen 20 and the support plate 30 together. The bonding layer 40 is formed of a pressure sensitive adhesive, an adhesive, or the like.

FIG. 2 is a diagram illustrating the layer configuration of the reflective screen 20 of the present embodiment.
In FIG. 2, it passes through a point A (see FIGS. 1A and 1B) that is the geometric center (center of the screen) of the observation screen (display area) of the reflection screen 20, and is parallel to the vertical direction of the screen. FIG. 2 shows an enlarged part of a cross section perpendicular to the screen surface (parallel to the thickness direction).
As shown in FIG. 2, the reflective screen 20 includes a surface layer 25, a base material layer 24, a lens layer 23, and a reflective layer 22 in order from the image source side (observer side) in the thickness direction.
The base material layer 24 is a sheet-like member serving as a base material for forming the lens layer 23. A surface layer 25 is integrally formed on the image source side of the base material layer 24, and a lens layer 23 is integrally formed on the back side (back side).
The base material layer 24 has a light diffusing layer 241 containing a diffusing material and a colored layer 242 containing a coloring material such as a pigment or a dye. The base material layer 24 of this embodiment is formed by integrally laminating a light diffusion layer 241 and a colored layer 242 by coextrusion molding.
In the present embodiment, as shown in FIG. 2, in the base material layer 24, the light diffusion layer 241 is on the back side and the coloring layer 242 is positioned on the image source side. The diffusion layer 241 may be positioned on the video source side and the colored layer 242 may be positioned on the back side.

The light diffusion layer 241 is a layer that contains a light transmissive resin as a base material and contains a light diffusing material. The light diffusion layer 241 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 241 include PET (polyethylene terephthalate) resin, PC (polycarbonate) resin, MS (methyl methacrylate / styrene) resin, MBS (methyl methacrylate / butadiene / styrene) resin, TAC ( Triacetyl cellulose) resin, PEN (polyethylene naphthalate) resin, acrylic resin and the like are preferably used.

As the diffusing material contained in the light diffusion layer 241, particles made of resin such as acrylic resin, epoxy resin, or silicon resin, inorganic particles, and the like are preferably used. Note that the diffusion material may be a combination of an inorganic diffusion material and an organic diffusion material. This diffusing material is preferably substantially spherical and has an average particle diameter of about 1 to 50 μm. Moreover, it is preferable that the range of the particle size of the diffusing material suitable for use is 5 to 30 μm.
The thickness of the light diffusion layer 241 is preferably about 100 to 2000 μm, although it depends on the screen size of the reflection screen 20 and the like. The light diffusion layer 241 preferably has a haze value in the range of 85 to 99%.

The colored layer 242 is a layer colored with a dark colorant such as black so as to have a predetermined light transmittance. The colored layer 242 has a function of improving the contrast of an image by absorbing unnecessary external light such as illumination light incident on the reflective screen 20 and reducing the black luminance of the displayed image.
As the colorant of the colored layer 242, a dark dye such as gray or black, a pigment, a metal salt such as carbon black, graphite, black iron oxide, or the like is preferably used.
As a resin which is a base material of the coloring layer 242, a PET resin, a PC resin, an MS resin, an MBS resin, a TAC resin, a PEN resin, an acrylic resin, or the like can be used.
The colored layer 242 preferably has a thickness of about 30 to 1000 μm, although it depends on the screen size of the reflective screen 20 and the like.

FIG. 3 is a diagram illustrating details of the lens layer 23 and the reflective layer 22 of the present embodiment.
FIG. 3A shows a state in which the lens layer 23 is observed from the front side on the back side, and the reflection layer 22 is omitted for easy understanding. FIG. 3B shows an enlarged part of the cross section shown in FIG. FIG. 3C shows an enlarged perspective view of the lens layer on which the reflective layer is formed. In FIG. 3B and FIG. 3C, the base material layer 24 and the surface layer 25 located on the image source side of the lens layer 23 are omitted for easy understanding.

The lens layer 23 is a light-transmitting layer provided on the back side of the base material layer 24, and a plurality of unit lenses 231 are arranged concentrically around the point C as shown in FIG. The circular Fresnel lens shape is provided on the back side surface. In this circular Fresnel lens shape, the point C which is the optical center (Fresnel center) is outside the area of the screen (display area) of the reflective screen 20 and is located below the reflective screen 20.
In the present embodiment, the lens layer 23 will be described by taking an example in which a circular Fresnel lens shape is provided on the surface on the back side. However, the present invention is not limited to this, and the unit lenses 231 are arranged in the screen vertical direction along the screen surface. It is good also as a form which has the made linear Fresnel lens shape.

2 and 3B, the unit lens 231 is parallel to the direction orthogonal to the screen surface (thickness direction of the reflection screen 20) and is a cross section in a cross section parallel to the arrangement direction of the unit lenses 231. The shape is a substantially triangular shape.
The unit lens 231 is convex on the back side, and includes a lens surface 232 and a non-lens surface 233 that faces the lens surface 232.
In the present embodiment, in the usage state of the reflection screen 20, the unit lens 231 has the lens surface 232 positioned above the non-lens surface 233 across the vertex t.

As shown in FIG. 3B, the angle formed by the lens surface 232 of the unit lens 231 with a surface parallel to the screen surface is α. Further, the angle formed by the non-lens surface 233 and the surface parallel to the screen surface is β (β> α). Furthermore, the arrangement pitch of the unit lenses 231 is P, and the lens height of the unit lenses 231 (the dimension from the apex t in the thickness direction of the screen to the point v that becomes the valley bottom between the unit lenses 231) is h.
In order to facilitate understanding, in FIG. 2 and the like, the arrangement pitch P and the angles α and β of the unit lenses 231 are shown to be constant in the arrangement direction of the unit lenses 231. However, the unit lenses 231 according to the present embodiment have a constant arrangement pitch P or 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 unit lenses 231. Accordingly, the lens height h also fluctuates.
The arrangement pitch P is not limited to this, and the arrangement pitch P may be changed gradually along the arrangement direction of the unit lenses 231. The size of the pixel of the video source LS that projects the video light L, the video source, and the like The LS projection angle (the incident angle of the image light on the screen surface of the reflection screen 20), the screen size of the reflection screen 20, the refractive index of each layer, and the like can be changed as appropriate.

The lens layer 23 is integrally formed on the back side surface of the base material layer 24 (in this embodiment, the light diffusion layer 241 side) by an ultraviolet curable resin such as urethane acrylate or epoxy acrylate. The lens layer 23 may be formed of another ionizing radiation curable resin such as an electron beam curable resin.
The unit lenses 231 of the present embodiment are formed so that the arrangement pitch P is in the range of 50 to 200 μm, the lens height h is in the range of 0.5 to 60 μm, and the angle α of the lens surface 232 is 0.5 to. The angle β of the non-lens surface 233 is formed in the range of 45 to 90 °.

The reflection layer 22 is a layer having an action of reflecting light. The reflection layer 22 has a sufficient thickness for reflecting light, and is formed on at least a part of the lens surface 232 of the unit lens 231.
The reflection layer 22 of this embodiment is formed on the lens surface 232 and the non-lens surface 233 as shown in FIG. 2 and FIG. Specifically, the reflection layer 22 covers the back side of the lens layer 23 and is formed so as to fill a boundary between the unit lenses 231 that are convex on the back side, that is, a point v that becomes a valley bottom. Thereby, the reflective layer 22 can make the unevenness | corrugation of the back side of a lens layer substantially flat, and can stick the support plate 30 more stably via the joining layer 40. FIG.
Here, as described above, the lens height h of the unit lenses 231 varies as the distance from the point C that becomes the Fresnel center in the arrangement direction of the unit lenses 231, but at the point v that becomes the valley bottom between the unit lenses 231. The thickness of the reflective layer 22 in the thickness direction of the lens layer 23 is formed with a dimension within a range of 10 to 120% with respect to the lens height h of each unit lens 231 in order to achieve the above-described effect more effectively. It is preferable.

The reflective layer 22 is formed on the lens surface 232 by spray-coating the lens surface 232 with a paint containing a highly light-reflective scale-like metal thin film 22a such as aluminum (details will be described later). ). The reflective layer 22 has a surface perpendicular to the thickness direction of the scale-like metal thin film 22a disposed substantially parallel to the lens surface 232, and the image light L incident on the lens surface 232 is appropriately directed to the viewer side. Can be reflected. Here, “substantially parallel” means not only the case where the surface perpendicular to the thickness direction of the metal thin film 22a is completely parallel to the lens surface 232, but also the inclination with respect to the lens surface 232 is in the range of −10 ° to + 10 °. It includes things that include some cases. Further, the scale-like metal thin film 22a means that the shape (outer shape) viewed from the thickness direction of the metal thin film 22a is a scale-like shape. The scale-like shape is not only a scale-like shape but also an elliptical shape or , Including a circular shape, a polygonal shape, and an irregular shape obtained by pulverizing a thin film.
Here, as the property classification of the scale-like metal thin film, there are a leafing type, a non-leafing type, a resin coating type, etc., which are each characterized by metallic luster, concealment, adhesion, orientation, etc. For example, a metallic luster is important, but a resin coating type is preferable in consideration of adhesion, orientation, and the like.

The metal thin film 22a has an average of eight or more layers on the entire lens surface of each of the unit lenses, in order to sufficiently ensure the reflection efficiency of the image light and prevent the back side of the reflection layer 22 from being seen through. It is desirable to be laminated. The reflective layer 22 provided with eight or more metal thin films 22 a described above may be provided on some lens surfaces 232 of the lens surfaces 232 of the plurality of unit lenses 231, or all the lens surfaces 232. May be provided.
In order to efficiently reflect incident video light, the reflection layer 22 preferably has a regular reflectance Rt of 50% <Rt <70% and a diffuse reflectance Rd of 10% <Rd <50%.

The coating material forming the reflective layer 22 is composed of a scale-like metal thin film 22a, a binder, a drying aid, a control agent, and the like. This paint preferably has a viscosity in the range of 50 to 1000 [cp] (measurement temperature 23 degrees Celsius) from the viewpoint of easy application with a spray gun.
This metal thin film 22a is aluminum formed in a scale shape, and the thickness dimension thereof is formed in the range of 15 to 150 nm, more preferably in the range of 20 to 80 nm. In addition, the metal thin film 22a has an average value of dimensions in the vertical and horizontal directions orthogonal to the thickness direction (hereinafter referred to as vertical and horizontal dimensions) equal to the lens height h of the unit lens 231, that is, 0. It is preferably formed to 35 to 78 μm. Here, the equivalent to the lens height h is not only when the average value of the vertical and horizontal dimensions of the metal thin film is equal to the lens height h, but also when it approximates the lens height h (for example, the lens height h -30% to + 30% size range).

Here, if the metal thin film 22a is disposed substantially parallel to the non-lens surface 233, when the external light is incident on the non-lens surface 233, the external light is reflected by the non-lens surface 233 and the observer side. May result in a decrease in the contrast of the video. Therefore, by making the average value of the vertical dimension and the horizontal dimension of the metal thin film 22a equal to the lens height h as described above, when the paint is applied to the back side of the lens layer 23, the metal thin film 22a , It can be prevented from being arranged substantially parallel to the non-lens surface 233. Thereby, even if external light injects into the non-lens surface 233, the reflection layer 22 can be diffused in the edge part of a metal thin film, and can suppress as much as possible that it reflects in an observer side.
The metal thin film 22a is preferably contained within a range of 3 to 15% by weight with respect to the weight of the entire coating material from the viewpoint of ensuring the light reflecting function as the reflecting layer.

The binder is a transparent bonding agent composed of a thermosetting resin. In the present embodiment, the binder uses a urethane-based thermosetting resin, but the binder is not limited to this, and an epoxy-based thermosetting resin may be used, or an ultraviolet curable resin or the like may be used. May be. The binder may be used as a two-component curable type by adding a curing agent. If it is a urethane resin, polyisocyanate or the like can be used, and if it is an epoxy resin, amines or the like can be used. Can be used.
The drying aid is a solvent that adjusts the drying time of the paint applied to the lens layer to a predetermined time, and is a so-called slow drying solvent. In the present embodiment, a predetermined amount of the drying aid is included in the coating so that the time until drying of the coating applied to the back side of the lens layer 23 is approximately one hour. As the drying aid, for example, a mixed solvent of propylene glycol monomethyl ether acetate, ethylene glycol monobutyl ether, diisobutyl ketone, and 3-methoxy-1-butyl acetate can be used.
The control agent is a solvent that controls the orientation of the metal thin film 22a contained in the paint. When the control agent is contained in the paint, the metal thin film 22 a can be disposed substantially parallel to the lens surface 232. As the control agent, for example, silica, alumina, aluminum hydroxide, acrylic oligomer, silicone or the like can be used.

The surface layer 25 is a layer provided on the image source side (observer side) of the base material layer 24. The surface layer 25 of the present embodiment forms the outermost surface of the reflection screen 20 on the image source side.
The surface layer 25 of the present embodiment has a hard coat function and an antiglare function, and an ultraviolet curable resin (for example, urethane acrylate) having a hard coat function is provided on the surface of the base layer 24 on the image source side. The ionizing radiation curable resin is applied so that the film thickness of the coating film is about 10 to 100 μm, and the fine uneven shape (mat shape) is cured by transferring it to the surface of the resin film. Is shaped and formed.

The surface layer 25 is not limited to the above example, and one or more necessary functions such as an antireflection function, an antiglare function, a hard coat function, an ultraviolet absorption function, an antifouling function, and an antistatic function are appropriately selected. Can be provided. Further, a touch panel layer or the like may be provided as the surface layer 25.
Further, as the surface layer 25, a layer having an antireflection function, an ultraviolet absorption function, an antifouling function, an antistatic function, or the like may be provided as a separate layer between the surface layer 25 and the base material layer 24.
Further, the surface layer 25 is a layer separate from the base material layer 24 and may be bonded to the base material layer 24 by an adhesive material (not shown) or the like, and is opposite to the lens layer 23 of the base material layer 24. It may be formed directly on the side (video source side) surface.

Returning to FIG. 2, the state of the image light and the external light incident on the reflection screen 20 of this embodiment will be described. In FIG. 2, the refractive index of the surface layer 25, the colored layer 242, the light diffusing layer 241, and the lens layer 23 is assumed to be equal to facilitate understanding, and the light of the light diffusing layer 241 with respect to the image light L1 and the external light G. The diffusion action and the like are omitted.
As shown in FIG. 2, most of the image light L <b> 1 projected from the image source LS enters from below the reflection screen 20, passes through the surface layer 25 and the base material layer 24, and is a unit lens 231 of the lens layer 23. Incident to

Then, the image light L1 enters the lens surface 232, is reflected by the reflective layer 22, travels toward the observer O, and exits from the reflective screen 20 in a substantially front direction. Therefore, since the image light L1 is efficiently reflected and reaches the observer O, a bright image can be displayed.
On the other hand, unnecessary external light G (G 1, G 2) such as illumination light is incident mainly from above the reflection screen 20 and passes through the surface layer 25 and the base material layer 24 as shown in FIG. Is incident on the unit lens 231.
A part of the external light G1 enters the non-lens surface 233, but is diffused at the end of the metal thin film 22a of the reflective layer 22 formed on the back side of the non-lens surface 233 and reaches the observer O side. Even so, the amount of light is much smaller than that of the image light L1. Further, a part of the external light G2 is reflected by the lens surface 232 and mainly travels to the lower side of the reflection screen 20, so that it does not reach the observer O side directly. Significantly less than the image light L1. Further, a part of the external light enters the reflective screen 20 and is absorbed by the colored layer 242. Therefore, the reflective screen 20 can suppress a decrease in the contrast of the image due to the external light G1, G2, and the like.
From the above, according to the reflective screen 20 of the present embodiment, a bright and good image can be displayed even in a bright room environment.

Here, an example of the manufacturing method of the reflective screen 20 of this embodiment is demonstrated.
FIG. 4 is a diagram for explaining an example of the manufacturing method of the reflection screen 20 of the present embodiment.
As shown in FIG. 4A, the light diffusing layer 241 and the colored layer 242 are integrally formed by co-extrusion molding a resin containing a diffusing material and a resin containing a coloring material with a predetermined thickness, respectively. The base material layer 24 is formed by molding. Here, it is assumed that the base material layer 24 has a web shape.

Next, as shown in FIG. 4B, an ultraviolet curable resin such as urethane acrylate is applied on the surface of the base material layer 24 on the image source side (in this embodiment, the surface on the colored layer 242 side). Then, a fine uneven shape (mat shape) is cured by transferring it to the surface of the resin film to form a surface layer 25 having a fine uneven shape on the surface. In the present embodiment, the surface layer 25 has a surface roughness in the range of 0.1 to 3 μm and a haze value in the range of 5 to 20%. Thereby, the base material sheet V in which the surface layer 25 is laminated on the base material layer 24 is completed.
Note that a masking material (not shown) may be detachably bonded onto the surface layer 25 and may be flowed to the next step. As the masking material, for example, a transparent or substantially transparent sheet-like member can be used, and has a function of preventing the surface layer 25 from being stained or damaged in the subsequent manufacturing process.

Next, the surface layer 25 and the base material layer 24 (base material sheet V) are cut into a predetermined size to form a single wafer.
And as shown in FIG.4 (c), the lens layer 23 is formed in the surface used as the back surface side of the base material sheet V (surface in this embodiment by the side of the light-diffusion layer 241) by the ultraviolet-ray shaping | molding method etc. .
The lens layer 23 has a circular Fresnel lens shape filled with an acrylic ultraviolet curable resin on the surface of the base material sheet V on the side of the base material layer 24 (in this embodiment, the surface on the light diffusion layer 241 side). It is formed by pressing a molding die to be formed, irradiating it with ultraviolet rays and curing it, and then releasing from the molding die (details will be described later).

Next, as shown in FIG. 4D, the reflective layer 22 is formed by spraying the paint containing the scaly metal thin film 22a on the back side of the lens layer 23 with a spray gun (not shown). Application of the paint is performed by moving the spray gun from the lower end portion in the vertical direction of the screen to the upper end side at a predetermined moving pitch (for example, 70 mm pitch) while moving the lens layer 23 in the horizontal direction of the screen. At this time, the direction of the spray gun is preferably substantially perpendicular to the lens surface 232 in order to facilitate the arrangement of the metal thin film 22 a substantially parallel to the lens surface 232.
Finally, the reflective screen 20 is completed by peeling the masking material or the like from the surface layer 25 or performing a subsequent process such as a further cutting process.

Next, the details of the lens layer forming step in FIG.
FIG. 5 is a diagram for explaining the details of the molding process of the lens layer. FIG. 5A is a diagram illustrating a state in which the resin stacked on the molding die is pressed through the base sheet V, and FIG. 5B is a diagram illustrating the base material on the molding die. FIG. 4 is a diagram illustrating a laminate in which a lens layer is formed on a sheet V. FIG.5 (c) is a figure which shows the state by which the conductive cloth was arrange | positioned on the laminated body before releasing from a metal mold | die for shaping | molding. Each drawing in FIG. 5 is a cross section parallel to the arrangement direction of the unit lenses of the lens layer formed by the molding die and parallel to the thickness direction.
Here, in each drawing of FIG. 5, the vertical direction of the molding die is the X direction, the horizontal direction is the Y direction, and the thickness direction is the Z direction. These directions are formed by this molding die. This corresponds to the screen vertical direction, the screen horizontal direction, and the thickness direction of the lens layer 23 (reflection screen 20). Further, the + Z side in the thickness direction is the front side of the molding die 50, and the −Z side is the back side of the molding die 50.

First, the configuration of the molding die 50 used for molding the lens layer 23 will be described.
The molding die 50 is a die for forming the lens layer 23 on the base material layer 24 (base material sheet V), and as shown in FIG. 5A, a molding space portion 51, an excess resin receiving portion 52, and the like. Is provided.
The molding space 51 is a space that is recessed from the surface of the molding die 50 into a shape corresponding to the lens shape of the lens layer 23 of the reflective screen 20. The space is filled with resin and the base sheet V is pressed. As a result, the lens layer 23 is formed on the base material layer 24.
The surplus resin receiving portion 52 is a portion that receives surplus resin that is an excess of the resin filled in the molding space portion 51. The surplus resin receiving portions 52 are respectively provided at the edge portions of the four sides of the molding die 50 formed in a substantially rectangular shape when viewed from the thickness direction.

Next, details of the molding process of the lens layer 23 will be described.
First, as shown in FIG. 5A, the resin is uniformly applied to the entire surface of the space 51 of the molding die 50, and is placed on the + X side end portion and the left and right direction (Y direction) end portions. The base material sheet V is disposed on the base material layer 24 so that the base material layer 24 faces downward, and is pressed by the rotating roller R.
Then, the molding die 50 is moved in the + X direction by a movable stage (not shown) so that the rotating roller R rotates and the resin pressed through the base sheet V becomes the base sheet V and the molding die. Between 50, it mainly flows from the + X side to the -X side. At this time, the resin also flows in the left-right direction (Y direction).
Here, as shown in FIG. 5B, most of the flowing resin is filled in the molding space 51, but the surplus resin (surplus resin) that could not be filled is It flows into the surplus resin receiving part 52 and accumulates between the base material sheet V (base material layer 24) and the surplus resin receiving part 52.

Next, the poured resin is irradiated with ultraviolet rays and cured to mold the lens layer 23, and the laminate U composed of the surface layer 25, the base material layer 24, and the lens layer 23 is released from the molding die 50. To do.
At this time, the above-described surplus resin is cured around the lens layer 23, but when the laminate U is released from the molding die 50, the excess resin is cut off from the lens layer 23 and the molding die 50. It may remain in the surplus resin receiving portion 52.
Here, since the laminated body U is formed of a material (resin) having no conductivity, the surface layer 25, the base material layer 24, and the lens layer 23 are each easily charged with static electricity. Therefore, when the laminated body U is released from the molding die 50, if the excess resin is torn off from the lens layer 23, fragments of the excess resin or uncured portions of the excess resin are caused by the static electricity. In some cases, the lens layer 23 is attracted to and adhered to the layer 23, and the lens layer 23 of the laminate U is damaged or soiled. Further, in the subsequent process of forming the reflective layer 22, the coating material for forming the reflective layer 22 may not properly adhere to the lens layer 23 due to charged static electricity, resulting in coating unevenness.

Therefore, in the present embodiment, when the laminated body U is released from the molding die 50, the conductive cloth (conductive member) 60 is used. The conductive cloth 60 is a cloth formed from conductive fibers. In this embodiment, the outer shape viewed from the thickness direction is rectangular.
As shown in FIG. 5 (c), before releasing the laminate U from the molding die 50, the conductive cloth 60 is disposed so as to cover the laminate U, and the laminate U and the conductive material are electrically conductive. The cloth 60 is brought into contact. Then, the laminated body U is released from the molding die 50 together with the conductive cloth 60. By doing so, static electricity charged in the laminated body U flows to the conductive cloth 60 side, and the amount of static electricity charged in the laminated body U can be greatly reduced, and the laminated body U is removed from the molding die 50. When the mold is released, even if the excess resin is broken, it is possible to suppress the fragments of the excess resin and the uncured portion from adhering to the lens layer 23. Further, also in the subsequent formation process of the reflective layer 22, it is possible to prevent the coating material forming the reflective layer 22 from being properly attached to the lens layer 23 due to charged static electricity and causing uneven coating.

Here, it is desirable that the conductive cloth 60 is formed so that the outer dimensions (vertical dimension and horizontal dimension) viewed from the thickness direction are substantially equal to those of the base material layer 24 (laminated body U). By forming substantially the same, it is possible to cover the conductive cloth 60 on almost the entire surface of the laminated body U, and to reduce the static electricity charged in the surface of the laminated body U by flowing uniformly to the conductive cloth 60 side. it can.
Here, the external dimensions viewed from the thickness direction of the conductive cloth 60 are substantially equal to the base material layer 24 (laminated body U), and the external dimensions of the conductive cloth 60 and the base material layer 24 are completely equal. This includes not only the case but also the case where the vertical dimension and the horizontal dimension forming the outer shape of the conductive cloth 60 are 70% to 100% of the vertical dimension and the horizontal dimension of the base material layer 24, respectively. If the longitudinal dimension or the lateral dimension of the conductive cloth 60 is less than 70% with respect to the dimension of the base material layer 24, the area covered with the conductive cloth 60 becomes too narrow and the electrostatic charging is performed. Since the effect of reducing the amount is lowered, it is not desirable. Moreover, when the vertical dimension or the horizontal dimension of the conductive cloth 60 is larger than 100% with respect to the dimension of the base material layer 24, the conductive cloth 60 becomes too large with respect to the laminated body U (base material layer 24). This is not desirable because it causes troubles in the release work of the laminated body U.
As the conductive cloth 60, for example, Sanderlon manufactured by Nippon Kashiwa Dyeing Co., Ltd. can be used.

Further, the static electricity charged in the laminated body U can be reduced by using the conductive string 61 instead of using the conductive cloth 60 as the conductive member.
FIG. 6 is a diagram illustrating an example of the arrangement of conductive strings with respect to the laminated body. Fig.6 (a) is a top view which shows the state which has arrange | positioned the electroconductive string on the laminated body U before releasing from a metal mold | die for shaping | molding. 6B is a cross-sectional view taken along the line bb of FIG. 6A and corresponds to FIG. 5C.

The conductive string 61 is a string formed from conductive fibers.
As shown in FIG. 6 (a), before releasing the laminated body U from the molding die 50, a plurality of conductive strings 61 are arranged in combination in a lattice shape so as to cover the laminated body U, The laminated body U is released from the molding die 50 together with the conductive string 61. By doing so, as in the case of using the conductive cloth 60 described above, the amount of static electricity charged on the laminate U by the conductive string 61 can be greatly reduced, and the laminate 50 can be formed from the molding die 50. When U is released, even if the excess resin is broken, it is possible to suppress the fragments of the excess resin and the uncured portion from adhering to the lens layer 23. Further, also in the subsequent formation process of the reflective layer 22, it is possible to prevent the coating material forming the reflective layer 22 from being properly attached to the lens layer 23 due to charged static electricity and causing uneven coating.

Furthermore, since the conductive cord 61 is arranged in a lattice shape, static electricity charged in the laminated body U is reduced by flowing uniformly to the conductive cord 61 side, and charging of static electricity remaining in the surface of the laminated body U is reduced. The amount distribution can be made uniform. As a result, it is possible to more effectively suppress the paint forming the reflective layer 22 from properly adhering to the lens layer 23 and causing uneven coating on the reflective layer 22.
In addition, the conductive cord 61 has an interval between adjacent conductive cords 61 of, for example, 30 to 50 mm from the viewpoint of more uniformly reducing the electrostatic charge amount in the plane of the laminated body U. It is desirable to be placed.
In addition, the conductive string 61 may be arranged in a lattice shape by combining a plurality of pieces in advance, and may be arranged on the laminated body U, or arranged individually on the laminated body U one by one, You may make it form in a grid | lattice form.

The conductive cloth 60 and the conductive string 61 described above may be grounded (earthed). When the conductive cloth 60 and the conductive string 61 are grounded, the amount of static electricity charged in the stacked body U can be more effectively reduced.
The conductive cloth 60 is grounded by, for example, providing a protruding portion that protrudes outward from the edge of a part of the outer peripheral edge of the conductive cloth 60 and bringing it into contact with a grounded molding die. The lead wire (conductive wire) may be connected to the outer peripheral edge of the conductive cloth 60 and the other end of the lead wire may be grounded.
The conductive cord 61 is grounded by, for example, lengthening at least one of the plurality of conductive cords 61 formed in a lattice shape and bringing it into contact with a grounded molding die. Alternatively, one end of a lead wire (conductive wire) may be connected to the end of the conductive string 61 and the other end of the lead wire may be grounded.

(Evaluation of electrostatic charge)
Next, in the release process of the laminate, the laminate (Example) that was released using a conductive cloth and the laminate (Comparative Example) that was released without using a conductive member such as a conductive cloth. The amount of static electricity remaining in each was measured, and the difference due to the presence or absence of a conductive cloth was evaluated. Further, a coating layer for forming the reflective layer was applied to the lens layers of the laminates of the examples and comparative examples to form the reflective layer, and whether or not coating unevenness occurred in the reflective layer was also evaluated.
FIG. 7 is a diagram showing details of measurement of the amount of charge charged to static electricity of the laminates of the examples and comparative examples. FIG. 7A is a diagram showing measurement points of the electrostatic charge amount of the laminates of Examples and Comparative Examples, and FIG. 7B is a diagram of the charge amount measuring device for the laminates of Examples and Comparative Examples. It is a figure explaining an arrangement state.

As shown in FIG. 7 (a), the electrostatic charge amount of each example and comparative example was measured using a charge amount measuring device (Kasuga Denki Co., Ltd., digital electrostatic potential measuring device KSD-1000). The vicinity of the four corners (measurement points 1 to 4) of the surface on the lens layer side of the laminate is measured.
In addition, the presence or absence of occurrence of coating unevenness was confirmed by visual recognition by an operator. The measurement results are summarized in Table 1 below.
Each laminate of each example and comparative example has a total thickness of about 1630 μm (surface layer: about 30 μm, base material layer: about 1500 μm, lens layer maximum thickness: about 100 μm), and external dimensions of 2380 × 1400 mm.
In addition, the molding die for molding the lens layer of each laminate of each example and comparative example is grounded.

The laminate of the comparative example was released from the molding die without using a conductive member such as a conductive cloth. Therefore, in the laminate of the comparative example, the charge amounts due to static electricity in the vicinity of the four corners (measurement points 1 to 4) are −26.4 [kV], −16.5 [kV], and −52.2 [kV], respectively. ], -38.3 [kV], and the average value thereof was -33.4 [kV].
Further, when a reflective layer was formed on the laminate of the comparative example by coating, coating unevenness was observed in the reflective layer.

On the other hand, the laminate of Example 1 was released from the molding die using a conductive cloth having a thickness of about 200 μm and an outer dimension of 2300 × 1000 mm. The outer shape of the conductive cloth used for releasing the laminate of Example 1 is substantially the same as the laminate (base material layer), more specifically, slightly smaller than the outer shape of the base material layer. The vertical dimension and the horizontal dimension are about 97% of the vertical dimension forming the base material layer and about 71% of the horizontal dimension. In the laminated body of Example 1, the charge amounts due to static electricity in the vicinity of the four corners (measurement points 1 to 4) are −10.9 [kV], −7.7 [kV], and −7.6 [kV, respectively. ], -11.2 [kV], and the average value of these was -9.4 [kV].
Further, when a reflective layer was formed on the laminate of Example 1 by coating, no coating unevenness was observed in the reflective layer.

The laminated body of Example 2 was released from the molding die using a conductive cloth having a thickness of about 200 μm and an outer dimension of 2300 × 1320 mm. The outer shape of the conductive cloth was the laminated body ( It is almost the same as the outer shape of the substrate layer 24). In the laminated body of Example 2, the charge amount due to static electricity in the vicinity of the four corners (measurement points 1 to 4) is −3.6 [kV], −5.3 [kV], and −4.5 [kV, respectively. ], -5.1 [kV], and the average value thereof was -4.6 [kV].
Further, when a reflective layer was formed on the laminate of Example 2 by coating, no coating unevenness was observed in the reflective layer.

The laminated body of Example 3 was released from the molding die using a conductive cloth having a thickness of about 200 μm and an outer dimension of 2300 × 1320 mm. The outer shape of the conductive cloth was the laminated body ( It is almost the same as the outer shape of the substrate layer 24). Further, the conductive cloth used for releasing the laminated body of Example 3 has a protruding portion that protrudes outward from the edge at a part of the edge forming the outer shape. When the conductive cloth is arranged so as to cover the laminated body before releasing the laminated body, the protruding portion thereof is in contact with the molding die and grounded (grounded). In the laminated body of Example 3, the charge amounts due to static electricity in the vicinity of the four corners (measurement points 1 to 4) are −5.0 [kV], −4.7 [kV], and −4.2 [kV, respectively. ], -4.4 [kV], and the average value thereof was -4.6 [kV].
Further, when a reflective layer was formed on the laminate of Example 3 by coating, no coating unevenness was observed in the reflective layer.

From the above, it was confirmed that the amount of electrostatic charge was significantly reduced in the laminates of the examples released from the molding die using the conductive cloth compared to the laminates of the comparative examples. In addition, it was confirmed that the coating unevenness generated in the reflective layer was prevented.
In addition, the charge amount at each measurement point of the laminate of the comparative example has a difference of about 36 [kV] at the maximum between the measurement points, resulting in variations in the distribution of the electrostatic charge amount in the plane of the laminate. It was. On the other hand, the laminate of Example 1 has a maximum of about 4 [kV] or less between each measurement point, and the laminate of Example 2 has a maximum of about 2 [kV] or less between each measurement point. The laminate of Example 3 had a maximum of about 1 [kV] or less between each measurement point, and it was also confirmed that the distribution of the electrostatic charge amount in the plane of the laminate tends to be uniform.

Here, the laminate of Example 3 is grounded (grounded) by contacting the conductive cloth with the molding die as described above, and thus more effective than the laminate of Example 1. It is considered that the amount of static electricity can be reduced.
In the laminate of Example 2, the conductive cloth is not directly grounded (grounded) as in Example 3. However, the amount of static electricity can be reduced as much as the laminate of Example 3. did it. This is because the outer shape of the conductive cloth is almost the same as that of the laminate (base material layer), so that when the operator releases the laminate from the molding die, It is considered that the contact is grounded (grounded) through the operator, or the area contributing to the discharge is increased due to the contact between the conductive cloth and the laminate, and the amount of discharge into the atmosphere is increased.
In addition, since the external shape of the conductive cloth used for releasing the laminated body of Example 1 is smaller than that of the laminated body (base material layer), the inner side of the outer peripheral edge of the laminated body is covered. It is arranged. Since the operator grabs the edge of the laminate not covered with the conductive cloth and releases the laminate from the molding die, the conductive cloth is grounded (grounded) through the operator. However, since the static electricity charged in the laminate (base material layer) flows to the conductive cloth side and is discharged into the atmosphere, the laminate of Example 1 is compared to the laminate of the comparative example. It is considered that the amount of static electricity can be sufficiently reduced.

As mentioned above, the mold release method of the laminated body of this embodiment has the following effects.
(1) The mold release method of the laminated body U is the base material sheet V in which the lens layer 23 is molded after the conductive cloth 60 (conductive string 61), which is a conductive member, is disposed on the base material sheet V. (Laminated body U) is released from the molding die together with the conductive cloth 60 (conductive string 61). Thereby, the mold release method of the laminated body U can greatly reduce the amount of static electricity charged in the laminated body U by the conductive cloth 60 (conductive string 61). When U is released, even if the excess resin is broken, it is possible to suppress the fragments of the excess resin and the uncured portion from adhering to the lens layer 23.
Further, in the subsequent process of forming the reflective layer 22, it is possible to prevent the coating material forming the reflective layer 22 from being properly attached to the lens layer 23 due to charged static electricity and causing uneven coating.
(2) The mold release method of the laminated body U can reduce the electrostatic charge amount of the laminated body more effectively by grounding the conductive cloth 60.
(3) Since the outer dimensions viewed from the thickness direction of the conductive cloth 60 are formed substantially the same as the outer dimensions of the laminated body U (base material layer 24), the conductive cloth 60 is formed from the laminated body U (base The material layer 24) can be covered over almost the entire surface, the distribution of the electrostatic charge amount in the plane of the laminate U can be made uniform, and the occurrence of uneven coating of the reflective layer can be further suppressed. Can do.
(4) Since the conductive string 61 is arranged in a lattice pattern on the laminate U (base material layer 24), the distribution of the electrostatic charge amount in the plane of the laminate U can be made uniform, The occurrence of uneven coating of the reflective layer can be further suppressed.

  Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and various modifications and changes can be made as in the modifications described later, and these are also included in the present invention. Within the technical scope. In addition, the effects described in the embodiments are merely a list of the most preferable effects resulting from the present invention, and the effects of the present invention are not limited to those described in the embodiments. It should be noted that the above-described embodiment and modifications described later can be used in appropriate combination, but detailed description thereof is omitted.

(Deformation)
(1) In the above-described embodiment, the example in which the conductive string 61 is arranged in a lattice shape as illustrated in FIG. 6 has been described, but is not limited thereto. For example, a plurality of conductive cords 61 may be arranged in parallel only in either the screen horizontal direction or the screen vertical direction of the laminate, and the screen horizontal direction (screen vertical direction). You may make it incline and arrange two or more. Furthermore, you may make it the electroconductive string arrange | positioned at a grid | lattice form incline with respect to a screen left-right direction (screen up-down direction).
(2) In the above-described embodiment, the example in which the conductive cloth 60 and the conductive string 61 are used as the conductive member has been shown. However, the present invention is not limited to this, and is formed from, for example, conductive fibers. A band-like body (conductive band) may be used, or a conductive net obtained by knitting conductive fibers in a net shape may be used.

DESCRIPTION OF SYMBOLS 1 Video display system 10 Reflective screen unit 20 Reflective screen 22 Reflective layer 22a Metal thin film 23 Lens layer 231 Unit lens 232 Lens surface 233 Non-lens surface 24 Base material layer 25 Surface layer 50 Molding die 51 Molding space part 52 Excess resin receiving Part 60 Conductive cloth 61 Conductive string LS Image source U Laminate V Base sheet

Claims (4)

The molding die is filled with a resin, a base material is placed on the resin and pressed, and then the resin is cured, and a laminate in which a lens layer is molded on the base material is formed into the molding die. A method for releasing a laminate that is released from a mold,
Disposing a conductive member on the laminate and releasing the laminate together with the conductive member from the molding die;
A method for releasing a laminate characterized by the above. In the release method of the laminated body of Claim 1,
The conductive member is grounded;
A method for releasing a laminate characterized by the above. In the mold release method of the laminated body according to claim 1 or 2,
The conductive member is a conductive cloth, and the outer dimension viewed from the thickness direction is formed substantially equal to the outer dimension of the laminate,
A method for releasing a laminate characterized by the above. In the mold release method of the laminated body according to claim 1 or 2,
The conductive member is a conductive string, and is disposed in a lattice pattern on the laminate.
A method for releasing a laminate characterized by the above.

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