JP3685433B2 - Film screen manufacturing apparatus and manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a film screen manufacturing apparatus and method for forming optical elements on both sides of a base film.
[0002]
[Prior art]
FIG. 5 is a diagram showing an example of a conventional film screen manufacturing apparatus (JP-A-3-64701, etc.).
The first mold roll 1 is a roll having a light incident side lens mold formed on the surface thereof. The 2nd metal mold | die roll 2 is a roll by which the light emission side lens type | mold was formed in the surface.
The 1st coating part 3 is a part which apply | coats the ultraviolet curing resin 102A between the 1st metal mold | die roll 1 and the light-incidence surface side of the base film 101. FIG. The 2nd coating part 4 is a part which apply | coats the ultraviolet curable resin 103A between the 2nd metal mold | die roll 2 and the light emission surface side of the base film 101. FIG.
[0003]
The first and second ultraviolet lamps 5 and 6 are light sources for irradiating and curing the ultraviolet curable resins 102A and 103A in a softened state.
The printing part 7 is a part for forming a light absorbing part (black stripe) BS or the like in a non-light emitting part on the light emitting side of the formed film screen 100.
R1 and R2 are rubber rolls, R3 is a take-up roll, and R4 is a guide roll.
[0004]
The ultraviolet curable resin 102 </ b> A is applied between the base film 101 and the first mold roll 1 by the first coating unit 3 and sealed at the right side of the first mold roll 1. Cured by irradiation of the first ultraviolet lamp 5. Therefore, the lens mold of the first mold roll 1 is transferred to the light incident side of the base film 101 to form the light incident side lens portion 102.
[0005]
Similarly, the UV curable resin 103 </ b> A is applied between the base film 101 and the second mold roll 2 by the second coating unit 4 and sealed on the left side of the second mold roll 2. In part, it is cured by irradiation of the second ultraviolet lamp 6. Therefore, the lens mold of the second mold roll 2 is transferred to the light output side of the base film 101 to form the light output side lens portion 103.
[0006]
At this time, the film screen 100 is formed by optically positioning the light incident side lens portions 102 and the light output side lens portions 103 formed on both sides of the base film 101.
[0007]
[Problems to be solved by the invention]
However, in the conventional technique described above, it is conceivable that the light incident side lens unit 102 and the light output side lens unit 103 are displaced due to the following causes.
(1) The first cause is a positional shift due to the thermal behavior (shrinkage) of the base film 101.
When the base film 101 on the first mold roll 1 is heated by the first ultraviolet lamp 5 (point A) and the base film 101 is expanded, the shape is formed. It shrinks by being cooled by the supplied UV curable resin 103A. After that, although it is heated by the second ultraviolet lamp 6 (point B), it is difficult to make the temperature of the base film 101 at this time equal to the temperature of the base film 101 at the point A.
As described above, when the mold roll is transferred, the lens molding point is different, and therefore, it is affected by the thermal behavior of the base film 101, which causes a positional shift.
[0008]
Further, the thermal behavior of the base film 101 is also affected by the temperature irregularities (variations) of the mold rolls 1 and 2 themselves. However, since it is difficult to make the temperatures of the first and second mold rolls 1 and 2 uniform, it is considered that a positional shift occurs. The current mold roll is temperature-controlled with an accuracy of about ± 1 ° C.
[0009]
It is known that the thermal behavior of the base film 101 is that the 1 m film shrinks by 10 to 30 μm with a temperature change of 1 ° C., and when the lens parts are molded on both sides of the base film 101, the positions of the lens parts on both sides It is difficult to adjust the required accuracy to about ± 3 μm.
[0010]
(2) The second cause is the displacement of the lens position due to the lateral movement of the base film 101 with respect to the first and second mold rolls 1 and 2.
The base film 101 is divided into the mold rolls 1 and 2 according to the inclination of the first mold roll 1 and the second mold roll 2 (see FIG. 6A), surface accuracy, the habit of the base film 101, and the like. When you change to 2, you may move sideways.
For this reason, as shown in FIG. 6B, a shift between the center O1 of the light incident side lens unit 102 and the center O2 of the light output side lens unit 103 occurs.
[0011]
The problem of the present invention is that, when an optical element such as a lens is formed on both surfaces of a base film using an ionizing radiation curable resin, the influence of the thermal behavior (thermal expansion / contraction) of the base film can be reduced (cancelled), It is an object to provide a film screen manufacturing apparatus and a manufacturing method capable of easily performing alignment with required accuracy.
[0012]
[Means for Solving the Problems]
In order to solve the above-mentioned problems, the invention of claim 1 includes: first and second molding die rolls that mold the first and second optical elements; resin application means that applies ionizing radiation curable resin; In a film screen manufacturing apparatus comprising: a resin curing means for irradiating and curing ionizing radiation to the ionizing radiation curable resin, and forming the first and second optical elements on both surfaces of the base film by the ionizing radiation curable resin. , a drying means for the first ionizing radiation curable resin applied to the base film by the resin coating device in a semi-dry state, the surface of the hand of the base film, a first ionizing radiation a semi dry state the cured resin layer is formed, the by the first and second molding die roll, said first and second optical elements and pattern transfer at the same point, the over the second molding die roll Curing the ionizing radiation curable resin is a manufacturing apparatus of a film screen and said.
[0013]
According to a second aspect of the present invention, in the film screen manufacturing apparatus according to the first aspect of the present invention, a first resin application unit that applies a first ionizing radiation curable resin to one surface of the base film; A second resin coating means for applying a second ionizing radiation curable resin layer to the molding die roll of 2, and a drying means for making the first ionizing radiation curable resin applied to the base film into a semi-dry state; A first molding die roll for molding the first optical element on the first ionizing radiation curable resin in a semi-dried state, and a resin curing means for curing the first and second ionizing radiation curable resin layers. The first and second molding die rolls are arranged so as to transfer the first and second optical elements at the same point, and the resin curing means is used for the second molding die. Ionizing radiation curing on mold roll It is a manufacturing apparatus of a film screen, characterized in that is disposed in a position to cure the fat layer.
[0014]
The invention according to claim 3, in the film production apparatus screen according to claim 1 or 2, before Symbol second molding die rolls, before Symbol second optical in more than a quarter of its circumference An apparatus for producing a film screen, wherein the elements are arranged so as to transfer a mold .
[0015]
According to a fourth aspect of the present invention, there is provided a film screen for forming a first optical element and a second optical element on both sides of a base film by transferring the mold onto an ionizing radiation curable resin by first and second molding die rolls. in the method, the surface of the hand of the base film, forming the ionizing radiation curable resin layer in a semi-dry state, by the first and second molding die roll, said first and second optical elements It is a method for producing a film screen , wherein the mold is transferred at the same point and the ionizing radiation curable resin is cured on the second molding die roll .
[0016]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in more detail with reference to the drawings and the like.
(First embodiment)
FIG. 1 is a schematic view showing a first embodiment of a film screen manufacturing apparatus according to the present invention.
In each of the embodiments described below, portions that perform the same functions as those of the above-described conventional example are given the same reference numerals at the end, and redundant descriptions are omitted as appropriate.
[0017]
The manufacturing apparatus 10 of the first embodiment uses a half-cure type resin as a first ultraviolet curable resin (hereinafter simply referred to as a UV resin) 102B. In the first coating unit 13, a liquid UV resin 102B is used. A drying unit 18 that is coated and dries the UV resin 102B in a semi-dry state is provided.
[0018]
Next, the operation of the manufacturing apparatus according to the first embodiment will be described together with the manufacturing method.
The first UV resin 102 </ b> B is applied by the first coating unit 13, and is in the state of a light incident surface (FIG. 1 (B)) is transferred at point A.
At the same time, the normal UV resin 103A is applied to the second mold roll 12 by the second coating unit 14, and the light exit surface shape (see FIG. 1C) is transferred.
At point B, the resins 102C and 103A on both surfaces of the base film 101 are cured by an ultraviolet lamp (hereinafter referred to as UV lamp) 15, and the shapes of the light incident side and light outgoing side lens portions 102 and 103 are molded.
[0019]
Further, in the light exit side lens unit 103, the light absorbing layer BS is formed in the non-light exit unit by the printing unit 17. When the non-light-emitting portion is a convex portion, gravure printing is performed, and when the non-light-emitting portion is a concave portion, wiping printing is performed.
According to the first embodiment, the influence of the thermal behavior of the base film 101 can be canceled by setting the transfer positions (points A) of the light incident side and light output side lens portions 102 and 103 to the same point.
[0020]
(Second Embodiment)
FIG. 2 is a schematic diagram showing a second embodiment of a film screen manufacturing apparatus according to the present invention.
In the manufacturing apparatus 20 of the second embodiment, the base film 101 is coated with the first and second UV resins 102 </ b> B and 103 </ b> B of the half-cure type on both surfaces in the first and second coating parts 23 and 24. .
At this time, the UV resins 102B and 103B are applied in a liquid state, but the drying unit 28 becomes semi-dried resins 102C and 103C in which only the surface layer is cured. The resins 102C and 103C are base films. When 101 passes the 1st and 2nd metal mold | die rolls 21 and 22, the light-incidence surface and the light emission surface shape (refer FIG. 2 (B), (C)) are transcribe | transferred.
[0021]
That is, at point A, the first and second mold rolls 21 and 22 transfer the lens shape to both surfaces of the base film 101, and after releasing from the mold rolls 21 and 22, Curing is performed by the 2UV lamps 25 and 26, and the light incident side and light exit side lenses 102 and 103 are formed.
According to the second embodiment, the shape transfer position (point A) is the same, and the light incident side and light output side lens portions can be formed at accurate positions regardless of the thermal behavior of the base film 101. .
[0022]
In each of the embodiments described above, the base film 101 may be PET, acrylic, polycarbonate, etc., and a film having a thickness of 15 to 300 μm can be used. Even if it is transparent, it is translucent (with a diffusing material). May be.
[0023]
As the UV curable resin 103A, a normal UV resin such as urethane, acrylic, urethane acrylate, or epoxy is used.
As the UV resins 102B and 103B, half-cure type UV resins are used. The UV resins 102B and 103B are required not to remain on the mold rolls 11 and 12 and to have no shape deformation even if the transferred lens shape is separated from the mold rolls 11 and 12. For example, a resin that is liquid at the time of coating but becomes a gel at the drying unit 18, and a resin that is liquid at the time of coating but whose surface layer is cured at the drying unit 18 and is shape-transferred by the mold rolls 12 and 13. Resins that are partially cured by insufficient UV irradiation can be used.
[0024]
Further, in the film screen manufactured by this manufacturing method, for example, as shown in FIG. 3, lenticular lenses are formed on both sides of the base film 101 as light incident side and light output side lens portions 102 and 103, A lenticular lens is formed as the light incident side lens portion 102 on the light incident side of the film screen 100A having the light absorbing layer BS formed on the non light emitting portion (protruding portion) and the base film 101, and the light emitting side non-light emitting portion ( A lenticular lens is formed as the light incident side lens portion 102 on the light incident side of the film screen 100B having the light absorbing layer BS formed on the projecting portion) and the base film 101, and a total reflection type convex lens is emitted on the light emitting side. A film screen (high contrast) formed as a side lens portion 103 and having a light absorbing layer BS formed in a non-light emitting portion. Such as clean) 100C, and the like.
Other examples include a linear Fresnel lens film screen having a light incident side micro lenticular lens described in JP-A-8-122922 and JP-A-8-190149.
[0025]
Further, as shown in FIG. 4, the projection television in which the film screen of the present embodiment is used has a Fresnel lens sheet 31 and a horizontal diffusing film lenticular lens sheet 32 which is the film screen of the present embodiment from the light source 40 side. And a vertical lenticular lens sheet 33 and a flat front panel 34 can be used.
When the light source 40 is a single tube type such as an LCD or DMD, the light exit side lens portion of the film lenticular lens sheet 32 may be omitted.
[0026]
Without being limited to the embodiment described above, various modifications and changes are possible, and these are also within the equivalent scope of the present invention.
For example, although an ultraviolet curable resin is taken as an example, other ionizing radiation curable resins such as an electron beam curable resin may be used.
[0027]
【The invention's effect】
As described above in detail, according to the present invention, a hand ionizing radiation curing resin as a semi-dry state, since the transfer position of the first and second molding die roll was the same point, the horizontal movement and / Alternatively, the thermal behavior can be prevented, and the positional accuracy of the optical elements molded on both sides of the base film can be improved.
[Brief description of the drawings]
FIG. 1 is a schematic view showing a first embodiment of a film screen manufacturing apparatus according to the present invention.
FIG. 2 is a schematic view showing a second embodiment of a film screen manufacturing apparatus according to the present invention.
FIG. 3 is a view showing an example of a film screen manufactured by the manufacturing apparatus according to the embodiment.
FIG. 4 is a view showing an example of a transmission screen using a film screen manufactured by the manufacturing apparatus according to the embodiment.
FIG. 5 is a view showing a film screen manufacturing apparatus according to a conventional example.
FIG. 6 is a diagram for explaining problems of a film screen according to a conventional example.
[Explanation of symbols]
1, 11, 21 First mold rolls 2, 12, 22 Second mold rolls 3, 13, 23 First coating parts 4, 14, 24 Second coating parts 5, 25 First ultraviolet lamp 15 Ultraviolet lamp 6, 26 Second ultraviolet lamp 7, 17, 27 Printing unit 18, 28 Drying unit 101 Base film 102A, 103A UV curable resin 102 Light incident side lens unit 103 Light output side lens unit BS Light absorption layer (black stripe)

Claims (4)

First and second molding die rolls for molding the first and second optical elements;
Resin application means for applying ionizing radiation curable resin
Resin curing means for curing the ionizing radiation curable resin by irradiating with ionizing radiation,
In a film screen manufacturing apparatus for forming the first and second optical elements on both surfaces of a base film with the ionizing radiation curable resin,
A drying means for semi-drying the first ionizing radiation curable resin applied to the base film by the resin applying means;
The hand of a surface of the base film, forming a first ionizing radiation curable resin layer in a semi-dry state, by the first and second molding die roll, said first and second optical elements same Mold transfer at one point ,
The apparatus for producing a film screen , wherein the ionizing radiation curable resin is cured on the second molding die roll . In the apparatus for manufacturing a film screen according to claim 1,
A first resin application means for applying a first ionizing radiation curable resin to one surface of the base film;
Second resin application means for applying a second ionizing radiation curable resin layer to the second molding die roll;
A drying means for semi-drying the first ionizing radiation curable resin applied to the base film;
A first molding die roll that molds the first optical element on the first ionizing radiation curable resin in a semi-dry state ;
Resin curing means for curing the first and second ionizing radiation curable resin layers ,
The first and second molding die rolls are arranged so as to transfer the first and second optical elements at the same point ;
The apparatus for producing a film screen, wherein the resin curing means is disposed at a position for curing the ionizing radiation curable resin layer on the second molding die roll . In the apparatus for manufacturing a film screen according to claim 1 or 2 ,
Before Stories second molding die roll apparatus for manufacturing a film screen, characterized in that it is arranged to mold transferring the pre-Symbol second optical element in more than a quarter of its circumference. In the method of manufacturing a film screen, the first and second molding die rolls are mold-transferred to an ionizing radiation curable resin and cured, and the first and second optical elements are molded on both sides of the base film.
The surface of the hand of the base film, forming the ionizing radiation curable resin layer in a semi-dry state, by the first and second molding die roll, said first and second optical elements at the same point Mold transfer ,
A method for producing a film screen , comprising: curing the ionizing radiation curable resin on the second molding die roll .

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