JP4161590B2 - Microlens manufacturing method, microlens, optical film, projection screen, and projector system - Google Patents

Microlens manufacturing method, microlens, optical film, projection screen, and projector system Download PDF

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Publication number
JP4161590B2
JP4161590B2 JP2002046292A JP2002046292A JP4161590B2 JP 4161590 B2 JP4161590 B2 JP 4161590B2 JP 2002046292 A JP2002046292 A JP 2002046292A JP 2002046292 A JP2002046292 A JP 2002046292A JP 4161590 B2 JP4161590 B2 JP 4161590B2
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Prior art keywords
light
microlens
formed
droplets
pattern
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JP2003240911A (en
Inventor
宏宣 長谷井
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セイコーエプソン株式会社
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Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a microlens manufacturing method, a microlens obtained thereby, an optical film provided with the microlens, a projection screen provided with the optical film, and a projector system, and more particularly, the size and shape of the microlens. It relates to what can be controlled arbitrarily.
[0002]
[Prior art]
In recent years, an optical element in which a large number of microlenses called microlenses are arranged has been provided. Examples of such an optical element include an element formed on the screen surface of a liquid crystal projector system to brighten an image, an optical fiber optical interconnection, a laser condensing element, and a solid-state imaging element for collecting incident light. There are things.
[0003]
By the way, the microlens which constitutes such an optical element has been conventionally molded by a molding method using a mold or a photolithography method.
In recent years, proposals have been made to apply the ink jet method used in printers and the like to form microlenses that are fine patterns.
[0004]
[Problems to be solved by the invention]
However, a molding method using a mold or a photolithography method requires a mold or a complicated manufacturing process for forming a microlens, which increases the cost, and an arbitrary shape. There was dissatisfaction that it was difficult to form the microlens at an arbitrary position.
In addition, according to a technique to which the ink jet method is applied, although it is easy to form the microlens at an arbitrary position, it is difficult to control the shape to a desired shape.
[0005]
The present invention has been made in view of the above circumstances, and the object of the present invention is to reduce the cost by eliminating the need for a mold and the like, and to provide a microlens manufacturing method and a microlens whose shape can be arbitrarily controlled. Another object is to provide a lens, an optical film including the microlens, a projection screen, and a projector system.
[0006]
[Means for Solving the Problems]
In order to achieve the above object, according to the method of manufacturing a microlens of the present invention, a light-transmitting resin is applied on a substrate having light transmittance and cured to form a convex microlens. It is characterized in that a plurality of droplets are ejected from one or a plurality of droplet ejection heads and applied to substantially the same location on a substrate having a substrate, and the shape of the microlens is controlled.
According to this method of manufacturing a microlens, a convex microlens made of a light-transmitting resin is formed using a droplet discharge head, so that a molding die is used as in the case of using a mold molding method or a photolithography method. A mold and a complicated manufacturing process are not required, and therefore the manufacturing cost can be reduced. In addition, since a plurality of droplets are ejected from one or a plurality of droplet ejection heads at substantially the same location on the light-transmitting substrate, the size of the microlens formed by the number of ejected droplets, etc. The shape can be controlled to be arbitrarily determined.
[0007]
In this microlens manufacturing method, a liquid-repellent pattern and a lyophilic pattern are formed in advance on the surface of a light-transmitting substrate, and one or a plurality of lyophilic patterns are formed at substantially the same location on the lyophilic pattern. Preferably, a plurality of droplets are ejected from the droplet ejection head and applied.
In this way, since the light-transmitting resin discharged and applied onto the lyophilic pattern has a small contact angle on the lyophilic pattern, it becomes a convex shape having a relatively large diameter. A micro lens having a large diameter can be formed.
[0008]
In the method for manufacturing the microlens, a liquid repellent pattern and a lyophilic pattern are formed in advance on the surface of a substrate having light transmittance, and one or a plurality of the liquid repellent patterns are formed at substantially the same location on the liquid repellent pattern. Preferably, a plurality of droplets are ejected from the droplet ejection head and applied.
In this way, the light-transmitting resin ejected and applied onto the liquid repellent pattern is in a high state without a large contact angle on the liquid repellent pattern, so that a convex shape having a relatively small diameter and thickness. Therefore, a microlens having a small diameter and a high height can be formed.
[0009]
Further, in the microlens manufacturing method, when a plurality of droplets are ejected from the droplet ejection head and applied, a curing process is not performed between the ejection and ejection of these droplets. It is preferable to perform the curing process for the first time after the entire amount of droplets to be discharged is applied.
In this way, after each droplet is ejected, it spreads on the light-transmitting substrate by its own weight, so that a microlens having a relatively large diameter can be formed by subsequent curing treatment.
[0010]
In the method of manufacturing a microlens, when a plurality of droplets are ejected from a droplet ejection head and applied, a curing process is performed at least once after ejecting these droplets at least once. It is preferable to perform the curing process again after applying the entire amount of droplets to be discharged.
In this case, by performing the curing process at least once after discharging the droplet at least once, the curing process is performed before the droplet is sufficiently spread by its own weight, and then the droplet is further discharged onto this. The liquid droplets can also be cured before spreading sufficiently, so that a microlens having a small diameter and a high height as a whole can be formed.
[0011]
The microlens of the present invention is manufactured by the above-described method.
According to this microlens, the manufacturing cost can be reduced by not requiring a molding die as described above, and the size and shape of the microlens to be formed can be arbitrarily determined depending on the number of ejected droplets. Since it is controlled so as to be able to be determined, it becomes a desired size and shape, thereby exhibiting the designed characteristics.
[0012]
In the optical film of the present invention, the light-transmitting substrate is made of a light-transmitting sheet or light-transmitting film, and the microlens is formed on the light-transmitting sheet or light-transmitting film. It is a feature.
According to this optical film, since the microlens exhibits the designed characteristics, the optical film has desired characteristics.
[0013]
The projection screen of the present invention is characterized in that the optical film is used as a lenticular sheet in a projection screen configured to include a Fresnel lens and a lenticular sheet.
According to this projection screen, since the optical film having the above-mentioned desired characteristics is used as the lenticular sheet, the optical film to be the lenticular sheet is projected onto the screen by having, for example, good diffusion performance. The image quality can be improved.
[0014]
In the projector system of the present invention, a light source, a light modulation unit that is arranged on the optical axis of the light emitted from the light source and modulates the light from the light source, and forms an image of the light modulated by the light modulation unit In the projector system comprising: an imaging optical system that performs imaging, and a screen that forms a projection image by copying an image formed by the imaging optical system, the projection screen of the present invention described above is used as the screen. It is characterized by becoming.
According to this projector system, since the projection screen is used, it is possible to improve the image quality of the projected image as described above, thereby improving the formation of the projected image on the screen. .
[0015]
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described in detail below.
First, the manufacturing method of the microlens of this invention is demonstrated. FIGS. 1A to 1C are diagrams for explaining a first example of a method for manufacturing a microlens according to the present invention. In these drawings, reference numeral 1 denotes a droplet discharge head, and 2 denotes light transmittance. It is a substrate which has.
In this first example, first, as shown in FIG. 1A, the liquid-repellent pattern 3 is formed on the surface of the substrate 2 where the microlens is not formed, and the lyophilic pattern 4 is formed where the microlens is formed. To do.
[0016]
Here, as the substrate 2, when the obtained microlens is applied to an optical film for a screen, for example, a cellulose resin such as cellulose acetate or propyl cellulose, a transparent resin such as polyvinyl chloride, polyethylene, polypropylene, polyester ( A light transmissive sheet or a light transmissive film made of a light transmissive resin) is used. When the microlens is applied to a microlens array or the like, the substrate is made of a transparent material (light transmissive material) such as glass, polycarbonate, polyarylate, polyethersulfone, amorphous polyolefin, polyethylene terephthalate, or polymethyl methacrylate. A substrate consisting of
[0017]
For the formation of the liquid repellent pattern 3 and the lyophilic pattern 4, for example, the following plasma polymerization method is preferably employed.
First, the liquid repellent treatment by plasma polymerization will be described. In this process, a raw material liquid for a liquid repellent process is prepared. As raw material liquid, C Four F Ten Or C 8 F 16 A liquid organic material composed of linear PFC such as is preferably used.
When such a raw material liquid is prepared, the vapor is converted into plasma in a plasma processing apparatus. Then, since the vapor | steam of this linear PFC was made into plasma, the coupling | bonding of a linear PFC is partly cut | disconnected and activated. When a part of the bond is cut in this way and the activated PFC reaches the surface of the substrate 2, these PFCs are polymerized with each other on the substrate 2 to form a fluororesin polymer film having liquid repellency.
[0018]
In addition, as a raw material liquid for the liquid repellent treatment, for example, decatriene can be used. In that case, CF activated by plasma treatment Four Alternatively, by adding oxygen, liquid repellency can be imparted to the resulting polymer film, whereby a liquid-repellent polymer film can be formed.
Moreover, fluorocarbon can also be used as a raw material liquid for the liquid repellent treatment. In that case, CF activated by plasmatization Four Even if a part of the fluorine in the fluorocarbon which is the raw material liquid is released by the plasma, the active fluorine is taken into the polymer film to be obtained, so that the fluororesin polymer film to be formed is repelled. Liquidity can be increased.
[0019]
In addition, when the polymer film thus obtained is irradiated with ultraviolet rays, the fluororesin polymer film is decomposed and removed from the surface of the substrate 2, whereby the irradiated part can be made lyophilic. Therefore, the lyophilic process can be performed by such an ultraviolet irradiation process. Then, by performing such ultraviolet irradiation using a mask that has been subjected to desired patterning in advance, a desired lyophilic pattern can be easily formed on the liquid repellent surface.
[0020]
By the plasma polymerization method, the liquid repellent pattern 3 and the lyophilic pattern 4 are formed on the surface of the substrate 2 as described above. Specifically, first, the surface of the substrate 2 is washed with ozone water or the like to remove organic substances adhering to the surface. Next, the surface of the substrate 2, that is, the entire upper surface serving as a non-processed surface, is subjected to the above-described liquid repellent treatment by plasma polymerization to make the surface of the substrate 2 a liquid repellent surface.
[0021]
Next, the surface of the substrate 2 that has become a liquid repellent surface is irradiated with ultraviolet rays using a mask corresponding to the lyophilic pattern 4 that is formed in advance, and a large number of liquid repellent surfaces are formed within the liquid repellent surface as shown in FIG. A lyophilic pattern 4 is formed. Here, these lyophilic patterns 4 are formed, for example, in a circular shape having a diameter of about 10 μm and arranged in a large number in the vertical and horizontal directions. In addition, by forming the lyophilic pattern 4 by ultraviolet irradiation in this way, the region other than the formed lyophilic pattern 4, that is, the region that has been subjected to the lyophobic treatment, becomes the lyophobic pattern 3 as it is. Further, the ultraviolet irradiation by using such a mask is performed by previously forming an alignment mark on the substrate 2 and positioning the mask with reference to the alignment mark.
[0022]
When the lyophobic pattern 3 and the lyophilic pattern 4 are formed in this way, a light-transmitting resin is disposed at substantially the same location on the lyophilic pattern 4 from the droplet discharge head 1 as shown in FIG. A plurality of droplets composed of the above are ejected and applied. As the droplet discharge head 1 to be used, for example, one having the following structure is used.
[0023]
As shown in FIG. 2A, the droplet discharge head 1 includes a nozzle plate 12 made of, for example, stainless steel and a vibration plate 13, and both are joined via a partition member (reservoir plate) 14. A plurality of spaces 15 and a liquid reservoir 16 are formed between the nozzle plate 12 and the diaphragm 13 by the partition member 14. Each space 15 and the liquid reservoir 16 are filled with a liquid material containing a light-transmitting resin, and each space 15 and the liquid reservoir 16 communicate with each other via a supply port 17. The nozzle plate 12 is formed with nozzles 18 for injecting a liquid material containing a light transmissive resin from the space 15. On the other hand, a hole 19 for supplying a liquid material to the liquid reservoir 16 is formed in the diaphragm 13.
[0024]
Further, a piezoelectric element (piezo element) 20 is joined to the surface of the diaphragm 13 opposite to the surface facing the space 15 as shown in FIG. The piezoelectric element 20 is positioned between a pair of electrodes 21 and is configured to bend so that when it is energized, it projects outward. The diaphragm 13 to which the piezoelectric element 20 is bonded in such a configuration is bent integrally with the piezoelectric element 20 at the same time so that the volume of the space 15 is increased. It is going to increase. Therefore, the liquid material corresponding to the increased volume in the space 15 flows from the liquid reservoir 16 through the supply port 17. Further, when energization to the piezoelectric element 20 is released from such a state, both the piezoelectric element 20 and the diaphragm 13 return to their original shapes. Therefore, since the space 15 also returns to its original volume, the pressure of the liquid material in the space 15 rises, and the droplet 22 containing the light transmissive resin is discharged from the nozzle 18 toward the substrate.
As a discharge method of the droplet discharge head 1, a method other than the piezo jet type using the piezoelectric element 20 may be used. For example, a method using an electrothermal transducer as an energy generating element may be adopted. .
[0025]
By using the droplet discharge head 1 having such a configuration, in this example, as shown in FIG. 1B, a liquid material containing a light-transmitting resin on the lyophilic pattern 4 on the surface of the substrate 2, that is, a lens material. As shown in FIG. 1C, the lens material 5 is formed by discharging a plurality of light-transmitting resin droplets 22. At this time, in this example, all droplets are ejected and applied without performing a curing process between the ejection of each droplet. In addition, although the capacity | capacitance per droplet 22 discharged from the droplet discharge head 1 changes also with the droplet discharge head 1 and the material to discharge, it is normally about 1pl-20pl. Further, the number of droplets to be ejected is set in advance, for example, three or five according to the size of the microlens to be formed.
[0026]
The light-transmitting resin used as the lens material includes acrylic resins such as polymethyl methacrylate, polyhydroxyethyl methacrylate and polycyclohexyl methacrylate, allyl resins such as polydiethylene glycol bisallyl carbonate and polycarbonate, methacrylic resins, polyurethane resins and polyesters. Thermoplastic resins or thermosetting resins such as resin, polyvinyl chloride resin, polyvinyl acetate resin, cellulose resin, polyamide resin, fluorine resin, polypropylene resin, and polystyrene resin. One kind of them is used, or a plurality of kinds are mixed and used.
[0027]
By blending such a light-transmitting resin with a photopolymerization initiator such as a biimidazole compound, the light-transmitting resin to be used may be used as a radiation irradiation curable type. That is, by blending such a photopolymerization initiator, radiation curable properties can be imparted to the light transmissive resin. Here, the radiation is a general term for visible light, ultraviolet light, far ultraviolet light, X-rays, electron beams, and the like, and particularly ultraviolet light is generally used.
[0028]
As described above, when all of the preset number of droplets are ejected, the lens material 5 composed of the ejected droplets wets the entire circular lyophilic pattern 4 and is placed on this pattern. Since it is returned to the lyophilic pattern 4 side so as to be repelled from the top of the lyophobic pattern 3 deviated from the lyophilic pattern 4, a good convex lens shape, that is, a substantially hemispherical shape is formed on the lyophilic pattern 4. .
[0029]
After that, the lens material 5 thus formed into a substantially hemispherical shape is subjected to a drying treatment such as a heat treatment, a decompression treatment, a heat decompression treatment, or the light transmissive resin is a radiation irradiation curable type as described above. In addition, by performing irradiation treatment with ultraviolet rays or the like, this is cured to obtain the microlens 6 of the present invention.
[0030]
In such a manufacturing method of the microlens 6, the light-transmitting resin discharged and applied onto the lyophilic pattern 4 is in a state where the contact angle is small and widened on the lyophilic pattern 4. The convex shape has a relatively large diameter corresponding to the size of the liquid pattern 4, and thus the microlens 6 obtained after curing can have a large convex shape having a large diameter. In addition, since the curing process is performed for the first time after all the droplets 22 to be ejected are applied, the droplets 22 are sufficiently spread on the lyophilic pattern 4 on the substrate 2 after being ejected. Therefore, also from this, the obtained microlens 6 can have a relatively large diameter and a good convex shape. In addition, since no molding die is required and there is almost no loss of material, the manufacturing cost can be reduced.
[0031]
In addition, since the microlens 6 of the present invention obtained by this manufacturing method has a relatively large diameter and a favorable convex shape, a good diffusion performance or a light collecting performance according to such a shape. It will have. In addition, since the size and shape can be further adjusted by the number of ejected droplets, the designed characteristics can be sufficiently exhibited.
[0032]
In such a manufacturing method, for example, after the first droplet 22 is ejected onto the lyophilic pattern 4, the entire droplet is applied (that is, between the ejection and ejection of each droplet). The curing process may be performed once or more, for example, each time each droplet 22 is discharged. By doing so, the liquid droplet 22 is cured before it sufficiently spreads by its own weight, and then the liquid droplets discharged thereon are also cured before sufficiently spreading, thereby suppressing the spread. A microlens with a high height can be formed. Therefore, according to such a method, since each droplet 22 is cured immediately after being ejected, the microlens obtained after curing has a relatively large diameter corresponding to the size of the lyophilic pattern 4. At the same time, it can have a high convex shape.
[0033]
Further, for the discharge of the light-transmitting resin droplets 22, the same droplet discharge head 1 may be used between the droplets 22, or a different one may be used. When the same one is used, the apparatus configuration including the droplet discharge head 1 can be simplified. On the other hand, when different ones are used, a large number of microlenses can be uniformly formed by ejecting droplets sequentially from these different droplet ejection heads 1. That is, for example, when one microlens is formed by three droplets, three droplet ejection heads 1 are prepared, and these droplet ejection heads are used for ejecting the first droplet, the second one And for the third droplet. Then, these three droplet discharge heads 1 are made to continuously discharge on a large number of lyophilic patterns 4 so that each droplet 22 is discharged and discharged between a large number of microlenses to be formed. The time interval can be made approximately the same. Accordingly, the degree of flow of each droplet over time can be made almost the same among a large number of microlenses to be formed, and as a result, the shape of the microlens obtained after curing can be made almost the same. Can do.
[0034]
Next, a second example of the microlens manufacturing method of the present invention will be described with reference to FIGS. This second example differs from the first example shown in FIGS. 1A to 1C in that droplets are ejected not on the lyophilic pattern but on the liquid-repellent pattern, and a microlens is provided here. The point is to form. That is, in this second example, first, as in the first example, the surface of the substrate 2 is washed with ozone water or the like to remove organic substances adhering to the surface. Subsequently, the surface of the substrate 2, that is, the entire upper surface serving as a non-processed surface, is subjected to the above-described liquid repellent treatment by plasma polymerization to make the surface of the substrate 2 a liquid repellent surface.
[0035]
Next, the surface of the substrate 2 having a liquid repellent surface is irradiated with ultraviolet rays using a mask corresponding to a lyophilic pattern formed in advance, and the lyophilic pattern 7 is formed in the liquid repellent surface as shown in FIG. Form. In addition, by forming the lyophilic pattern 7 by ultraviolet irradiation in this way, the region other than the formed lyophilic pattern 7, that is, the region that has been subjected to the lyophobic treatment, is used as the lyophobic pattern 8 as it is. Therefore, in the present example, unlike the first example, microlenses are formed on the liquid repellent pattern 8. In contrast to the first example, these liquid repellent patterns 8 are each formed into a circular pattern. These are formed by arranging a large number of them vertically and horizontally. However, as will be described later, the liquid repellent pattern 8 has a property that the liquid repellent pattern 8 has poor wettability with respect to the liquid droplets (light-transmitting resin) discharged thereon and does not spread. In order to form a microlens having the same size as that of the example, it is necessary to make it larger than the size (diameter) of the lyophilic pattern 4 of the first example.
[0036]
When the liquid repellent pattern 8 and the lyophilic pattern 7 are formed in this way, as shown in FIGS. 3B and 3C, the droplet discharge head 1 places the liquid repellent pattern 8 at substantially the same location on the liquid repellent pattern 8. A plurality of droplets 22 made of a light-transmitting resin are discharged and applied. At this time, in this example, the curing process is performed every time between the ejection of each droplet. Then, when all the droplets have been ejected, a final curing process is performed.
[0037]
When the first droplet 22 is ejected onto the liquid repellent pattern 8, the spread of the droplet 22 in the surface direction of the substrate 2 is restricted by the liquid repellent pattern 8 as shown in FIG. That is, the liquid repellent pattern 8 has poor wettability with respect to the liquid droplet 22 made of a light-transmitting resin. Therefore, the liquid droplet 22 attempts to make its surface area as small as possible, so that the liquid droplet 22 wets the liquid repellent pattern 8. This is because it can be prevented from spreading in the surface direction. In addition, in this example, after the droplet 22 is discharged, the droplet 22 on the substrate 2 is cured before the next discharge, so that the droplet 22 may spread in the surface direction over time. It is suppressed.
[0038]
In addition, since the droplet 22 ejected after the first droplet 22 is landed almost immediately above the cured droplet 22, the cured droplet 22 is naturally a newly ejected droplet. Due to the good wettability with respect to 22, the newly ejected droplet 22 hardly protrudes and spreads on the liquid repellent pattern 8, and is a cured droplet as shown in FIG. 22 will be put on. Then, the discharge of the preset number of droplets 22 is sequentially repeated in this way, thereby obtaining a microlens 9 having a sufficiently high height as shown in FIG.
[0039]
In such a manufacturing method of the microlens 9, the light-transmitting resin discharged and applied on the liquid-repellent pattern 8 is in a high state without having a large contact angle on the liquid-repellent pattern 8. A convex shape having a relatively small diameter and thickness (height) is obtained, and therefore, the diameter can be small and the height can be increased. In addition, since the curing process is performed every time between the ejection of each droplet 22, the curing process is performed before the droplet 22 sufficiently spreads by its own weight, and then the liquid ejected on this The droplet 22 is also cured before it is sufficiently spread. Therefore, also from this, the microlens 9 having a small diameter and a high height as a whole can be formed.
[0040]
Moreover, since the microlens 9 of the present invention obtained by this manufacturing method has a small diameter and a high height, the microlens 9 has good diffusion performance or light collection performance according to such a shape. It becomes. In addition, since the size and shape can be further adjusted by the number of ejected droplets, the designed characteristics can be sufficiently exhibited.
[0041]
In this manufacturing method, the curing process is performed between the ejections of the respective droplets. However, in the method of this example, until all the droplets are applied (that is, each liquid is discharged). It is only necessary to perform at least one curing process between the ejection of the droplets). Even in this case, the curing process is performed before the droplet 22 sufficiently spreads by its own weight, A microlens with a high height can be formed so that the spread is suppressed.
[0042]
In the second example, the curing process may not be performed until all the droplets are ejected, and the curing process may be performed for the first time after the entire amount of ejected droplets is applied. In this way, after each droplet is ejected, it spreads on the substrate by its own weight, but since it is on the liquid repellent pattern 8, its spread is limited, so that the diameter is relatively small and the height is high. Microlenses can be formed.
It should be noted that the discharge of the droplet 22 in this example may be performed using the same droplet discharge head 1 as in the first example, or using a different one. Also good.
[0043]
Further, in the method for manufacturing a microlens of the present invention, the droplets 22 made of a light-transmitting resin are ejected onto a lyophilic pattern or a liquid-repellent pattern, but without such lyophilic or liquid-repellent treatment. The droplet 22 may be directly discharged onto the substrate 2, and in this case, the size and shape of the microlens to be formed can be arbitrarily determined depending on the number of droplets to be discharged. Therefore, a microlens having the required diffusion performance or light collection performance can be formed.
[0044]
Further, in the present invention, two or more kinds of light transmissive resins having different refractive indexes are prepared, and these droplets are divided for each light transmissive resin and applied onto the substrate 2 so that different light transmissive resins can be obtained. You may make it form the microlens laminated | stacked on two layers or three layers or more. If formed in this way, the obtained microlens not only refracts the transmitted light between the substrate and the microlens and between the microlens and the outside environment thereof, but also within the microlens. Refraction can be caused between the layers, so that higher diffusion performance or light collection performance is exhibited.
[0045]
Further, the liquid repellent treatment and the lyophilic treatment are not limited to the plasma polymerization method, and various other methods can be employed. For example, liquid repellent treatment or lyophilic treatment by changing the wettability as used in the pattern forming method disclosed in JP-A-11-344804 can be employed.
[0046]
This pattern forming method is a method of optically forming a pattern. A pattern forming body provided with a photocatalyst containing layer containing a substance whose wettability is changed by the action of a photocatalyst is formed on a base material. A pattern forming body in which the content of a substance whose paintability is changed by the action of the photocatalyst is formed on the photocatalyst-containing layer, the photocatalyst-containing layer is formed on the base material, and the photocatalyst-containing layer is decomposed and removed by the action of the photocatalyst The pattern forming body having a layer formed thereon, or the pattern forming body in which a composition layer comprising a photocatalyst, a substance decomposed by the action of the photocatalyst by exposure of the pattern, and a binder is formed on the substrate is exposed to the pattern. In this method, the paintability of the surface is changed by the action of the photocatalyst.
Even by such a method, a liquid repellent treatment or a lyophilic treatment can be performed by forming a photocatalyst-containing layer on a substrate, irradiating light to act a photocatalyst, and changing the wettability of the surface. It is.
[0047]
Next, an example in which the microlens 6 (9) obtained by such a manufacturing method is applied to an optical film will be described.
This optical film is formed by using a light transmissive sheet or a light transmissive film as the substrate 11, and as shown in FIGS. 4A and 4B, a large number of microlenses 30 are formed on the substrate 11. The optical films 31a and 31b of the present invention are configured by arranging the microlenses 6 and 9 vertically and horizontally.
[0048]
Here, in the optical film 31a shown in FIG. 4A, the microlenses 30 are densely vertically and horizontally, that is, the distance between the adjacent microlenses 30 is smaller than the diameter of the microlens 30 (the outer diameter of the bottom surface). Are arranged in close proximity to each other so as to be sufficiently small and used as a lenticular sheet for a screen as will be described later, while the optical film 31b shown in FIG. The microlens 30 is sparser than the optical film 31a, that is, the microlens 30 has a lower density per unit area than the optical film 31a, and is used as a screen scattering film as described later. It is.
[0049]
Such optical films 31a and 31b are formed with the microlenses 30 (6, 9) exhibiting a good diffusion effect as described above, and thus have a good diffusion performance. Become a film.
In particular, in the optical film 31a shown in FIG. 4 (a), since the microlenses 30 are densely arranged in the vertical and horizontal directions, the optical film 31a exhibits better diffusion performance and is extremely good as a lenticular sheet for a screen. It becomes.
On the other hand, in the optical film 31b shown in FIG. 4B, since the microlenses 30 are sparsely arranged vertically and horizontally, a scattering film for scattering the reflected light once incident on the screen is used. The light incident from the projection side is favorably scattered with respect to the reflected light without being excessively scattered.
[0050]
FIG. 5 is a view showing an example of a projector screen provided with these optical films 31a and 31b. Reference numeral 40 in FIG. 5 denotes a projector screen (hereinafter abbreviated as a screen). The screen 40 is configured such that a lenticular sheet 43 is affixed on a film base 41 via an adhesive layer 42, and a Fresnel lens 44 and a scattering film 45 are further disposed in this order on the screen 40. .
[0051]
The lenticular sheet 43 is configured by the optical film 31a shown in FIG. 4A, and is configured by densely arranging a large number of microlenses 30 on a light transmitting sheet (substrate 11). . Further, the scattering film 45 is constituted by the optical film 31b shown in FIG. 4B. Compared with the lenticular sheet 43, the microlens 30 is sparsely disposed on the light transmitting sheet (substrate 11). It is arranged and arranged.
[0052]
In such a screen 40, since the optical film 31a is used as the lenticular sheet 43 and the optical film 31b is used as the scattering film 45, the screen 40 is relatively inexpensive. Further, since the optical film 31a that becomes the lenticular sheet 43 has a good diffusion performance, the image quality of the image projected on the screen 40 can be improved, and the optical film 31b that becomes the scattering film 45 has a good diffusion. By having the performance, the visibility of the image projected on the screen 40 can be enhanced. Further, the scattering film basically needs to transmit the projection light from the projector, but in this scattering film 45, the density of the individual convex microlenses per unit area is lower than that of the lenticular sheet. Therefore, as described later, it is possible to sufficiently ensure good transparency of the projection light from the projector.
[0053]
The screen of the present invention is not limited to the example shown in FIG. 5. For example, the optical film 31 a may be used only as the lenticular sheet 43, and the optical film 31 b is used only as the scattering film 45. May be used.
Even in these screens, for example, by using the optical film 31a as the lenticular sheet 43, since the lenticular sheet 43 has a good diffusion performance, the image quality of the image projected on the screen can be improved. it can. Further, by using the optical film 31b as the scattering film 45, since the scattering film 45 has a good diffusion performance, the light transmitted through the scattering film 45 is reflected and is incident on the scattering film 45 again. When the light is reflected (reflected), the incident light (reflected light) is scattered by the scattering film 45, so that regular reflection of the incident light can be suppressed. Therefore, the visibility of the image projected on the screen can be improved.
[0054]
FIG. 6 is a diagram showing an example of a projector system including the projector screen 40 shown in FIG. 5, and reference numeral 50 in FIG. 6 denotes a projector system. The projector system 50 includes a projector 51 and the screen 40 described above. The projector 51 includes a light source 52, a liquid crystal light valve 53 that is disposed on the optical axis of the light emitted from the light source 52 and modulates the light from the light source 52, and an image of the light that has passed through the liquid crystal light valve 53. And an imaging lens (imaging optical system) 54.
Here, it is not limited to a liquid crystal light valve, and any means that modulates light may be used. For example, a means that modulates light from a light source by driving a minute reflecting member (controlling a reflection angle) may be used.
[0055]
In the projector system 50, since the projection screen 40 shown in FIG. 5 is used as the screen, the visibility of the projected image is enhanced as described above, and the image projected on the screen 40 is also improved. The image quality can be improved, and furthermore, good scattering of the projection light from the projector 51 can be sufficiently secured by the scattering film 45 made of the optical film 31b.
[0056]
In the projector system 50 as well, the screen to be used is not limited to the screen 40 shown in FIG. 5, and as described above, the screen using the optical film 31 a only as the lenticular sheet 43 may be used. The optical film 31b may be used only as the scattering film 45.
[0057]
The microlens of the present invention is not only applied to the optical films 31a and 31b as described above, but can be applied to other various optical elements and optical components. For example, the present invention can be applied to optical interconnection of optical fibers, a condensing element for laser, and a condensing microlens in a liquid crystal device or a solid-state imaging element.
[0058]
【The invention's effect】
As described above, according to the method for manufacturing a microlens of the present invention, the manufacturing cost can be reduced, and one or a plurality of droplets are disposed at substantially the same location on a light-transmitting substrate. Since a plurality of droplets are ejected from the ejection head, it is possible to control so that the size and shape of the microlens formed can be arbitrarily determined according to the number of ejected droplets.
According to the microlens of the present invention, the manufacturing cost can be reduced, and the size and shape of the microlens to be formed can be arbitrarily determined according to the number of ejected droplets. By having the size and shape, the characteristics as designed are exhibited.
[0059]
According to the optical film of the present invention, since the microlens exhibits the designed characteristics, the optical film has desired characteristics.
According to the projection screen of the present invention, since the optical film having the desired characteristics is used as the lenticular sheet, the optical film to be the lenticular sheet has a good diffusing performance, and is projected on the screen. Image quality can be improved.
According to the projector system of the present invention, since the projection screen is used, the image quality of the projected image can be improved as described above, thereby improving the formation of the projected image on the screen. Can do.
[Brief description of the drawings]
FIGS. 1A to 1C are views for explaining a first example of a manufacturing method of a microlens according to the present invention in the order of steps, FIG. 1A is a plan view of a main part, and FIGS. c) is a sectional side view of an essential part.
2A and 2B are diagrams for explaining a schematic configuration of a droplet discharge head, in which FIG. 2A is a perspective view of a main part, and FIG.
FIGS. 3A to 3D are views for explaining a second example of the microlens manufacturing method of the present invention in the order of steps, FIG. 3A is a plan view of a main part, and FIGS. d) is a sectional side view of an essential part.
4 (a) and 4 (b) are perspective views of a main part showing an example of an optical film of the present invention.
FIG. 5 is a side sectional view of an essential part showing an example of a projector screen of the present invention.
FIG. 6 is a diagram for explaining a schematic configuration of an example of a projector system according to the invention.
[Explanation of symbols]
1 ... Droplet discharge head
2 ... Substrate having optical transparency
3, 8 ... Liquid repellent pattern
4, 7 ... lyophilic pattern
6, 9, 30 ... micro lens
22: Droplet
31a, 31b ... Optical film
40 ... Screen for projector
43 ... Lenticular sheet
45. Scattering film
50 ... Projector system
51 ... Projector
52 ... Light source
53 ... Liquid crystal light valve
54 ... Imaging lens (imaging optical system)

Claims (5)

  1. When a light-transmitting resin is applied onto a substrate having light transmittance and cured to form a convex microlens,
    A liquid-repellent pattern and a lyophilic pattern are formed in advance on the surface of a light-transmitting substrate, and a plurality of droplets are ejected from one or a plurality of droplet discharge heads at substantially the same location on the liquid-repellent pattern. It is characterized in that it is discharged and applied, and at least once the droplets are discharged and then cured at least once, after the entire amount of discharged droplets is applied, the curing process is performed again. Manufacturing method of a micro lens.
  2. A microlens manufactured by the method according to claim 1.
  3. The optical substrate, wherein the light-transmitting substrate comprises a light-transmitting sheet or a light-transmitting film, and the microlens according to claim 2 is formed on the light-transmitting sheet or light-transmitting film. film.
  4. A projection screen comprising a Fresnel lens and a lenticular sheet, wherein the optical film according to claim 3 is used as the lenticular sheet.
  5. A light source, a light modulation unit that is arranged on the optical axis of the light emitted from the light source and modulates the light from the light source, and an imaging optical system that forms an image of the light modulated by the light modulation unit, In a projector system comprising a screen that forms a projected image by copying an image formed by the imaging optical system,
    5. A projector system comprising the projection screen according to claim 4 as the screen.
JP2002046292A 2002-02-22 2002-02-22 Microlens manufacturing method, microlens, optical film, projection screen, and projector system Expired - Fee Related JP4161590B2 (en)

Priority Applications (1)

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JP3719431B2 (en) 2002-09-25 2005-11-24 セイコーエプソン株式会社 Optical component, its manufacturing method, display device, and imaging element
JP4165244B2 (en) 2003-02-06 2008-10-15 セイコーエプソン株式会社 Manufacturing method of light receiving element
JP2004240361A (en) 2003-02-10 2004-08-26 Seiko Epson Corp Lens integrated optical fiber and method of manufacturing the same, optical module, and optical transfer means
US7601386B2 (en) 2003-07-11 2009-10-13 Seiko Epson Corporation Process for forming a film, process for manufacturing a device, electro-optical device and electronic equipment
JP4924785B2 (en) * 2004-03-26 2012-04-25 セイコーエプソン株式会社 MSM type light receiving element and manufacturing method thereof, optical module, and optical transmission device
US7416309B2 (en) 2004-12-30 2008-08-26 3M Innovative Properties Company Optical film having a surface with rounded structures
US7220026B2 (en) 2004-12-30 2007-05-22 3M Innovative Properties Company Optical film having a structured surface with offset prismatic structures
US7320538B2 (en) 2004-12-30 2008-01-22 3M Innovative Properties Company Optical film having a structured surface with concave pyramid-shaped structures
JP2006326541A (en) 2005-05-30 2006-12-07 Seiko Epson Corp Droplet injection method, head unit, droplet injection apparatus, electro-optical device, and electronic equipment
JP2007079325A (en) * 2005-09-16 2007-03-29 Hitachi Ltd Microlens array
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US9575229B2 (en) 2014-03-19 2017-02-21 Nike, Inc. Article having a plurality of optical structures
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Publication number Priority date Publication date Assignee Title
CN102147511A (en) * 2010-02-10 2011-08-10 新科实业有限公司 Method for manufacturing polymer micro-lens and collimator having polymer micro-lens
CN102147511B (en) * 2010-02-10 2014-09-24 新科实业有限公司 Method for manufacturing polymer micro-lens and collimator having polymer micro-lens

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