JP5055698B2 - Manufacturing method of light diffusing layer, manufacturing method of Fresnel lens sheet, manufacturing method of diffusing lens array sheet, and manufacturing method of transmissive screen - Google Patents

Description

  The present invention relates to a method of manufacturing a light diffusion layer, a Fresnel lens sheet, a diffusion lens array sheet used for a transmission screen of a rear projection display device such as a rear projection television, and a method of manufacturing a transmission screen. .

2. Description of the Related Art Conventionally, a rear projection television known as a rear projection display device equipped with a transmissive screen is a transmissive screen that has a substantially rectangular flat plate shape by reflecting video light projected from a projector as a light source by a reflecting mirror. By making the light incident on the rear surface, an observer positioned on the front surface side of the transmissive screen can observe the image light transmitted through the transmissive screen and emitted.
The transmission screen includes a Fresnel lens sheet that adjusts the direction of incident light to be emitted light, and a lenticular lens array sheet that diffuses the emitted light from the Fresnel lens sheet.
The Fresnel lens sheet in such a transmission screen includes a light diffusing plate for supplementing the diffusing action of the lenticular lens array sheet and a Fresnel lens that adjusts the direction of incident light to be emitted light. The lenticular lens array sheet includes a lenticular lens array that diffuses incident light in the left-right direction (horizontal direction) of the screen and a light diffusion plate that diffuses light in the vertical direction (vertical direction).

As a diffusion layer made of a diffusion film used for such a Fresnel lens sheet or a lenticular lens array sheet, there is one described in Patent Document 1, for example. In the transmissive screen described in Patent Document 1, a diffusion film having a diffusion curable resin layer in which a diffusing agent is mixed on one surface of a film base is disposed on the exit side of the lenticular lens array via an adhesive layer. Furthermore, the fine uneven surface shape treated surface is positioned on the surface on the light exit side of the diffusion film.
According to this method for producing a diffusion film, first, a diffusion curable resin layer mixed with a diffusion agent is applied to one surface of a film base material to obtain a diffusion film. Moreover, the fine uneven | corrugated shaped surface of a release layer is overlap | superposed on the uncured diffusion hardening type resin layer of a diffusion film using the transfer sheet which laminated | stacked the fine uneven surface shape processing layer and the release layer on another film base material. Then, ultraviolet rays are irradiated to cure the diffusion curable resin layer of the diffusion film, and at the same time, the fine uneven surface of the release layer is transferred to the diffusion curable resin layer of the diffusion film, and then the transfer sheet is peeled off. In this way, the diffusion film described above is obtained.
Moreover, as an example of another manufacturing method of a diffusion layer, as described in Patent Document 2, a method of forming a diffusion layer by applying and forming a coating liquid in which a light diffusion agent is mixed on a light diffusion base material Has been proposed.
Japanese Patent Laid-Open No. 2004-77781 JP 2003-215717 A

However, in the method for producing a diffusion layer described in Patent Document 1, as a pre-process for adhering a diffusion film to a lenticular lens array, a fine unevenness is formed on the surface after applying a diffusion curable resin layer mixed with a diffusion agent on a film substrate. Since a process for producing a diffusion film by transferring the surface shape treatment layer and curing the diffusion curable resin layer is required, there is a disadvantage that it takes time and costs.
In addition, the manufacturing method of Patent Document 2 has an advantage that the cost is relatively low because a resin material mixed with a light diffusing agent is directly applied to a transparent substrate of a Fresnel lens sheet. Since it is not flat, there is a drawback that the thickness cannot be controlled due to variation in thickness due to fine unevenness of the coated surface. Moreover, since it is simply applied to a coated surface such as a transparent substrate and dried, a light diffusing layer is applied (coating) when it is desired to form a matte surface, mirror surface, or antiglare surface on the surface of the light diffusing plate. There was a problem that the shape of the surface could not be controlled.

The present invention has been made in view of such a situation, and a manufacturing method of a light diffusing layer, a manufacturing method of a Fresnel lens sheet, a diffusing lens capable of reducing the manufacturing cost and controlling the thickness of the light diffusing layer. It is an object of the present invention to provide an array sheet manufacturing method and a transmission screen manufacturing method.
Another object of the present invention is to provide a method for manufacturing a light diffusing layer, a method for manufacturing a Fresnel lens sheet, a diffusing lens array, which can easily form various surface shapes such as a matte surface, a mirror surface, an antiglare surface, etc. It is to provide a sheet manufacturing method and a transmission screen manufacturing method.

The light diffusing layer manufacturing method according to the present invention includes a step of applying a thermoplastic resin mixed with a light diffusing agent on one surface of a substrate, and a mat surface processing, an antiglare surface processing or a mirror surface in advance on the surface in contact with the thermoplastic resin. A process in which the processed and fixed film is adhered to the thermoplastic resin, and a process in which the thermoplastic resin is pressurized with a heating roll through the film and heated to improve the fluidity and adhere to the substrate to level the film. And a step of forming a light diffusion layer in which the matte surface, the antiglare surface or the mirror surface is transferred with the film by cooling and curing the thermoplastic resin, and closely contacting the substrate.
According to the present invention, after applying a thermoplastic resin to a substrate, the fluidity of the resin is applied by adhering a film that has been subjected to mat surface processing, anti-glare surface processing, or mirror surface processing and fixed in advance on the surface of the resin. Thus, the film can be made to conform to the surface shape of the substrate, and the unevenness of the substrate surface and the variation in the coating thickness of the thermoplastic resin caused by the coating method can be suppressed with a heating roll, and the thickness can be leveled. And after giving heat, a thermoplastic resin can be cooled and hardened, and the light-diffusion layer of substantially uniform thickness can be formed on a board | substrate.

In addition, by pressing the thermoplastic resin through the film by a pressing means such as a roll, the fluid is pushed into the fine irregularities of the substrate, and the thickness can be controlled more uniformly.
In addition, when a thermoplastic resin mixed with a light diffusing agent is applied to one surface of the substrate, leveling by pressing the thermoplastic resin through the film and curing by heating can be performed simultaneously.
In addition, after the step of forming the light diffusion layer and closely contacting the substrate, the mat surface, anti-glare surface, mirror surface, or the like can be transferred to the light diffusion layer by removing the film that has been processed in advance on the surface that contacts the light diffusion layer. it can.
By bringing the film into close contact with the thermoplastic resin, it is possible to transfer the mat surface, anti-glare surface, mirror surface, or the like previously processed on the contact surface of the film with respect to the resin to the cured light diffusion layer.
Further, the film may be adhered to the light diffusion layer as a protective layer.
In this case, the film is integrated as a protective layer on the surface of the light diffusion layer.

In the Fresnel lens sheet manufacturing method according to the present invention, in the Fresnel lens sheet in which the first light diffusion layer is disposed on the incident side and the Fresnel lens is disposed on the emission side, the first light diffusion layer is defined in claims 1 to 4. It is manufactured by the manufacturing method of the light-diffusion layer in any one of 3 .
A Fresnel lens sheet can be manufactured by closely contacting the first light diffusion layer and the Fresnel lens manufactured by the above manufacturing method.
The method of manufacturing a diffusing lens array sheet according to the present invention is a diffusing lens array sheet in which a diffusing lens array is disposed on the incident side and a second light diffusing layer is disposed on the emitting side, and the second light diffusing layer is claimed. It is manufactured by the manufacturing method of the light-diffusion layer in any one of claim | item 1-3 .
A diffusion lens array sheet can be manufactured by closely contacting the second light diffusion layer manufactured by the above manufacturing method and the diffusion lens array.
The substrate may be an adhesive layer in close contact with the diffusing lens array, whereby the diffusing lens array sheet can be manufactured by sequentially laminating the adhesive layer and the second light diffusing layer on the diffusing lens array.

A transmission type screen manufacturing method according to the present invention is a transmission type screen in which a Fresnel lens sheet and a diffusing lens array sheet are arranged to face each other, and the Fresnel lens sheet is manufactured by the method of manufacturing a Fresnel lens sheet according to claim 4 , The diffusing lens array sheet is manufactured by the diffusing lens array sheet manufacturing method according to claim 5 or 6 .
The first light diffusing layer and the second light diffusing layer are respectively applied to the Fresnel lens and the diffusing lens array in a fluid state, applied with a film, and then cured and adhered to each other, thereby allowing the Fresnel lens sheet and the diffusing lens array to adhere. Sheets can be manufactured, and transmissive screens can be manufactured easily and at low cost.

According to the present invention, a light diffusing agent is applied to a substrate by curing in close contact with the film including a thermoplastic resin, the thickness of the light diffusion layer can be produced a light diffusion layer of substantially uniform thickness It can be controlled and has fewer manufacturing steps and lower costs than conventional manufacturing methods.

Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.
1 to 3 show a method for manufacturing a light diffusion layer according to the first embodiment. FIG. 1 is a horizontal sectional view of a transmission screen including the light diffusion layer manufactured according to this embodiment. FIG. 3 is a diagram illustrating a manufacturing process of a Fresnel lens sheet, and FIG. 3 is a diagram illustrating a coating process of a light diffusion layer on a transparent substrate.
In the first embodiment, a rear projection television as a rear projection display device has a casing (not shown) and a front side (right side in FIG. 1) exposed to the outside of the casing and a rear side ( A transmission screen 1 (see FIG. 1) having a substantially rectangular flat plate shape with the left side in FIG. 1 exposed to the inside of the housing, and image light with respect to the rear surface of the transmission screen 1 disposed in the housing. A projector (not shown) as a light source for projecting L, and at least one reflecting mirror (not shown) that is also disposed in the housing and deflects the optical path of the image light L projected from the projector. ing.

As shown in FIG. 1, the transmission screen 1 includes a Fresnel lens sheet 2 and a lenticular lens array sheet (diffuse lens array sheet) 3. The Fresnel lens sheet 2 includes a light diffusing plate 4 (light diffusing layer) for supplementing the diffusing action of the lenticular lens array sheet 3, and a Fresnel lens 5 that adjusts the direction of incident light to be emitted light. The lenticular lens array sheet 3 includes a lenticular lens array 7 (diffuse lens array) that diffuses light emitted from the Fresnel lens sheet 2 in the left-right direction (horizontal direction) of the screen, and light emitted from the lenticular lens array 7 on the screen. And a diffusion plate 8 that diffuses in the vertical direction (vertical direction).
The Fresnel lens sheet 2 and the lenticular lens array sheet 3 are in contact with each other from the back side (incident side, left side in FIG. 1) to the front side (outgoing side, right side in FIG. 1) of the transmissive screen 1 and are substantially parallel. Are arranged in order.

The Fresnel lens sheet 2 has a light diffusion plate 4 disposed on the incident side and a Fresnel lens 5 disposed on the exit side. The light diffusing plate 4 includes a light diffusing layer 10 in which a light diffusing agent is mixed and a transparent substrate 11 to which the light diffusing layer 10 is bonded. The light diffusing layer 10 is provided on the incident side of the image light L. The transparent substrate 11 is disposed on the emission side while being disposed. On the incident side surface of the light diffusion layer 10, a mat surface 10a having a fine uneven shape is formed in order to suppress scintillation.
The Fresnel lens 5 includes a plurality of unit lenses arranged concentrically. The Fresnel lens 5 passes through the center of the concentric circle formed by the plurality of unit lenses and extends along the normal line of the light diffusion plate 4, that is, the optical axis P1 of the Fresnel lens sheet 2. Pass through a position outside the long side of the light diffusing plate 4 (downward in FIG. 1) in the direction along the short side of the light diffusing plate 4 passing through the center P2 of the light diffusing plate 4 (the vertical direction of the screen). Are arranged as follows.
The image light L projected from the projector enters the Fresnel lens sheet 2 and exits toward the lenticular lens array sheet 3 as substantially parallel light.

The lenticular lens array sheet 3 includes a lens sheet main body 13 made of a thermoplastic resin that is a transparent material, for example, having a rectangular flat plate shape. A lenticular lens array 7 is provided on the image light incident side surface of the lens sheet main body 13, and a plurality of openings 9 and a plurality of light shielding layers 12 are alternately arranged on the exit side surface.
In the lenticular lens array 7, a plurality of cylindrical lenses (unit lenses) having a substantially semi-cylindrical shape are arranged substantially in parallel with each other, and the longitudinal direction of each cylindrical lens is substantially aligned with the vertical direction (vertical direction) of the screen. .
The lenticular lens array 7 collects and diffuses the incident video light L in the horizontal direction of the screen and emits it to the diffusion plate 8 as striped light. Further, in the present embodiment, the opening 9 is located in the condensing part of the video light L, and the light shielding layer 12 (black stripe) is located in the non-condensing part.

The diffusing plate 8 is composed of a light diffusing layer mixed with a light diffusing agent. One side on the incident side facing the lens sheet main body 13 faces the opening 9 and the light shielding layer 12, while one side on the emitting side It is a substantially flat surface.
In this embodiment, the diffusing plate 8 is made of a material cured by post-treatment such as heat treatment or active energy ray irradiation treatment, and has light diffusibility when mixed with a light diffusing agent. Instead of this, the diffusion plate 8 is made of, for example, a light-diffusing adhesive material or adhesive material mixed with a light diffusing agent, and a resin or glass plate for reinforcing the strength is used for the opening 9 and the light shielding layer 12. Alternatively, the lens sheet body 13 may be bonded.

Hereinafter, a method for manufacturing the Fresnel lens sheet 2 of the transmission screen 1 configured as described above will be described.
First, a solvent 19 containing an uncured active energy ray-curable resin 10c mixed with a light diffusing agent 10b on one surface 11a of a transparent substrate 11 made of a transparent MS plate shown in FIG. It is applied by a method such as coating or curtain coating (see FIG. 5B). If the film thickness of the light diffusing layer 10 formed by curing the active energy ray-curable resin 10c is too small, the adhesiveness to the transparent substrate 11 is lowered, and if it is too large, it becomes difficult to apply the solvent, so that the thickness is 20 to 40 μm. Thus, the thickness of the solvent 19 is set.
Here, as the light diffusing agent 10b, for example, resin beads or glass beads are used. If the average particle size of the light diffusing agent 10b is too small, the light scattering component becomes large. Conversely, if the average particle size is too large, the light scattering unevenness becomes large, so the average particle size is set to 5 to 30 μm. . In addition, if the amount of the light diffusing agent 10b added to the active energy ray curable resin 10c is too small, the diffusion characteristics become small, and if it is too large, the adhesiveness when the light diffusing layer 10 is cured decreases. The active energy ray-curable resin 10c is set to 1 to 30% by weight.
Moreover, as the active energy ray curable resin 10c, for example, an ultraviolet curable photopolymer is used. Specifically, a known adhesive containing an acrylic polymer, an acrylic monomer, a photoinitiator, and the like is used. As for the characteristics of such an active energy ray-curable resin 10c, fluidity is required in an uncured state, and for example, adhesiveness of cello tape (registered trademark) is good in order to ensure adhesion in a state after curing. It is required to be.

Next, the coating method of the light diffusion layer 10 shown in FIG. 2B will be described in detail based on FIG.
In FIG. 3A, a solvent 19 (hereinafter simply referred to as a solvent 19) containing an active energy ray-curable resin 10c mixed with a light diffusing agent 10b on one surface 11a of a transparent substrate 11 made of a transparent MS plate is used. It is applied by a method such as roll coating or curtain coating described above.
Here, since the transparent substrate 11 has fine irregularities on the surface 11a, the film thickness varies along the irregularities when the solvent 19 is applied. In addition, the film thickness varies depending on the coating method such as roll coating or curtain coating. Therefore, the light diffusion layer 10 after drying cannot obtain a uniform film thickness simply by applying the solvent 19.
Therefore, the overlay film 20 is brought into close contact with the solvent 19 in the next step (see FIG. 3B). Then, the pressure roll 21 is rolled to squeeze the overlay film 20, and the solvent 19 is pushed into the fine irregularities of the surface 11a of the transparent substrate 11 through the film 20 (see FIG. 3C). Therefore, the solvent 19 needs fluidity before and after the overlay film 20 is attached. Note that there is no need to squeeze the overlay film 20 with the pressure roll 21, and the film thickness of the light diffusion layer 10 is uniformly controlled by bringing the overlay film 20 into close contact with the solvent 19 applied to the transparent substrate 11. It may be.

  The overlay film 20 needs to be peelable from the light diffusing layer 10 that is UV transmissive and cured after UV irradiation. For example, a PET film is used. The overlay film 20 is set to a thickness of 10 μm to 100 μm, and if it is thicker than 100 μm, the film thickness of the light diffusion layer 10 is not uniform, and even if it is smaller than 10 μm, the effect of leveling the film thickness cannot be obtained. In addition, Preferably it shall be 25 micrometers or more. Further, the surface 20a of the overlay film 20 that comes into contact with the solvent 19 is previously fixed with a matte surface treatment. When the overlay film 20 is peeled after the light diffusing layer 10 is cured, the mat surface 10a is transferred to the surface of the light diffusing layer 10, and scintillation can be suppressed.

And as shown in FIG.3 (d), an active energy ray is irradiated from the active energy ray generation means 22, the overlay film 20 is permeate | transmitted, and the solvent 19 is irradiated. As a result, the active energy ray-curable resin 10c mixed with the light diffusing agent 10b is cured, and the light diffusing layer 10 is adhered and laminated to the surface 11a of the transparent substrate 11 due to its adhesiveness. In addition, when the overlay film 20 has the characteristic which does not permeate | transmit an active energy ray, the active energy ray generating means 22 is arrange | positioned at the transparent substrate 11 side, the transparent substrate 11 is permeate | transmitted, and an active energy ray is made into solvent 19 Can be irradiated.
Next, as shown in FIG. 3 (e), by releasing the overlay film 20 from the cured light diffusion layer 10, the light diffusion layer 10 having the mat surface 10a transferred to the surface and the transparent substrate 11 are formed. The provided light diffusing plate 4 can be obtained.

Next, the light diffusing plate 4 is placed in a concave mold (not shown) having a reverse shape of the Fresnel lens 5, and a flowable active energy ray-curable resin is poured into a Fresnel shape. The light diffusion layer 10 is integrated by being brought into close contact with the surface 11b on the opposite side of the transparent substrate 11 formed thereon. And it pressurizes from the mold of a Fresnel lens with the roll which is not illustrated, and spreads fluid active energy ray hardening type resin in a mold.
Next, the active energy ray is irradiated from the active energy ray generating means through the mold of the Fresnel lens or the light diffusion plate 4. As a result, the active energy ray-curable resin is cured and exhibits adhesiveness, and is in close contact with the transparent substrate 11 to form the Fresnel lens 5 (see FIG. 3C).
In this way, the Fresnel lens sheet 2 shown in FIG. 1 is manufactured. Then, the transmission type screen 1 is manufactured by disposing the lenticular lens array sheet 3 manufactured separately. In addition, what is necessary is just to manufacture the diffusion plate 8 provided in the lenticular lens array sheet 3 using appropriate manufacturing methods, such as the diffusion film shown in the prior art mentioned above.

Although the matte surface processing is performed on the contact surface of the overlay film 20 with the light diffusion layer 10 and transferred to the light diffusion layer 10 to obtain the mat surface 10a, the antiglare surface processing or mirror surface is used instead of the mat surface processing. It may be transferred to the surface of the light diffusion layer 10 by processing or the like.
The overlay film 20 is not necessarily peeled off after the light diffusing layer 10 is cured, and may be deposited as a protective layer to constitute a part of the Fresnel lens sheet 2.

As described above, according to the present embodiment, when the Fresnel lens sheet 2 is manufactured, the overlay film is obtained by directly applying the solvent 19 containing the active energy ray-curable resin 10c mixed with the light diffusing agent 10b to the transparent substrate 11. The film thickness of the light diffusion layer 10 after curing can be controlled almost uniformly by depositing 20 or by further pressing with a pressure roll 21. In addition, unlike the conventional manufacturing method, it is not necessary to manufacture a diffusion film in which a diffusion layer is previously applied to one side of a film substrate, and the manufacturing process is simplified and the manufacturing cost can be reduced.
Further, the matte surface 10a, anti-glare surface, mirror surface or the like can be produced by transferring the surface of the light diffusing layer 10 with the overlay film 20, or a part of the light diffusing layer 10 may be constituted by using the overlay film 20 as a protective layer. Control of the surface of the light diffusion layer 10 is also easy and can be manufactured at low cost.

Next, other embodiments and modifications of the present invention will be described. The same or similar parts and members as those of the above-described first embodiment are denoted by the same reference numerals, and the description thereof is omitted.
4 and 5 show a second embodiment of the present invention. FIG. 4 is a view showing the structure of a transmission screen, and FIG. 5 is a view showing a method for manufacturing a lenticular lens array sheet.
In the second embodiment, a light diffusion layer is provided by coating on both the Fresnel lens sheet 2 and the lenticular lens array sheet 31 constituting the transmission screen 30. That is, in the transmissive screen 30 shown in FIG. 4, the Fresnel lens sheet 2 is obtained by the manufacturing method according to the first embodiment described above, and this light diffusion layer 10 is referred to as a first light diffusion layer 10.
The lenticular lens array sheet 31 is provided with the lenticular lens array 7 on the image light incident side surface of the lens sheet body 13, and on the exit side surface, a plurality of concave portions 15 positioned in the image light condensing portion and a non-condensing state. A concavo-convex structure 14 is formed in which a plurality of convex portions 16 located in the portion are alternately arranged. A light shielding layer 17 that shields the non-light-condensing portion is provided in a stripe shape on the top surface of the convex portion 16 located in the non-light-condensing portion of the image light.
A transparent adhesive layer 32 is provided in which one surface is in close contact with the concavo-convex structure 14 including the light-shielding portion 17 without a gap. On the other flat surface 32a of the adhesive layer 32, a second light diffusion layer 33 made of an active energy ray curable resin 10b mixed with a light diffusion agent 10b by coating and curing is provided. The second light diffusion layer 33 may be composed of a hard coat layer.

Next, a manufacturing method of the lenticular lens array sheet 31 will be described with reference to FIG.
The concave and convex structure 14 in which a plurality of concave portions 15 and a plurality of convex portions 16 are alternately arranged on the surface on the emission side of the lenticular lens array 7 manufactured in advance is filled with a transparent adhesive layer 32 and the opposite surface. 32a is formed flat and cured (see FIG. 5A).
Then, as shown in FIG. 5 (b), a solvent 19 containing an active energy ray-curable resin 10 b mixed with a light diffusing agent 10 b is applied onto the surface 32 a of the adhesive layer 32. By depositing the overlay film 20 on the surface, the overlay film 20 is deformed following the fine irregularities of the surface 32a of the adhesive layer 32, so that the thickness of the solvent 19 can be controlled almost uniformly (FIG. 5 ( c)). Further, the pressure roll 21 may be used to roll the overlay film 20 to push the solvent 19 into the concavo-convex structure 14 to control the thickness to be more uniform.

Next, as shown in FIG. 5 (d), the active energy ray is irradiated from the active energy ray generating means 22 onto the solvent 19 through the overlay film 20. As a result, the active energy ray-curable resin 10c is cured, and a second light diffusion layer 33 in close contact with the permeable adhesive layer 32 is formed. Then, the overlay film 20 is peeled off as shown in FIG. The second light diffusion layer 33 is a hard coat layer having a predetermined hardness, and specifically, the pencil hardness is set to H or higher or 2H or higher.
As in the first embodiment, the contact surface of the overlay film 20 with the second light diffusion layer 33 is subjected to mat processing, anti-glare processing, mirror processing, etc., and the overlay film 20 is peeled to remove the second film. A mat surface or the like may be transferred to the light diffusion layer 33.
Alternatively, the overlay film 20 may be used as a protective layer without peeling off, or the overlay film 20 may be peeled off to cover another protective layer, an antireflection film, or the like.

As described above, the second embodiment also provides the same effects as the first embodiment. In particular, in this embodiment, the first and second light diffusion layers are formed by the overlay film 20 in order to manufacture the first light diffusion layer 10 and the second light diffusion layer 33 of the Fresnel lens sheet 2 and the lenticular lens array sheet 31 by coating. The film thickness control of the layers 10 and 33 and the surface control of the mat surface and the like can be performed, the manufacturing process can be further simplified, and the manufacturing cost can be reduced.
Instead of the method of manufacturing the lenticular lens array sheet 31 according to the second embodiment shown in FIG. 5, as a modification, the uneven structure 14 of the lenticular lens array 7 is filled with the adhesive layer 32 and then shown in FIG. The lenticular lens array sheet 31 may be manufactured by pressing and adhering the other surface 11b of the transparent substrate 11 to which the light diffusion layer 33 manufactured separately by the manufacturing method is adhered to the adhesive layer 32. Further, the manufacturing method of the present invention may be applied only to the second light diffusion layer 33 of the lenticular lens array sheet 31.

Next, a third embodiment of the present invention will be described with reference to FIG.
In the manufacturing method of the Fresnel lens sheet 2 according to the present embodiment, a thermoplastic resin 10d is used instead of the active energy ray-curable resin 10c constituting the first light diffusion layer 10. The solvent 35 containing the thermoplastic resin 10d requires fluidity before and after the overlay film 20 before thermosetting is attached. As the thermoplastic resin 10d, for example, an acrylic resin, a polyvinyl acetate resin, a polyvinyl butyral resin, a polyamide resin, or a thermoplastic polyurethane resin can be employed.
That is, in FIG. 6A, a solvent 35 (hereinafter simply referred to as a solvent 35) containing a thermoplastic resin 10d mixed with a light diffusing agent 10b is rolled on one surface 11a of a transparent substrate 11 made of a transparent MS plate. It is applied by an appropriate method such as a coat or curtain coat. When the solvent 35 is applied, the film thickness varies along the fine irregularities of the surface 11a of the transparent substrate 11 and also by a coating method such as roll coating or curtain coating. Therefore, a uniform film thickness cannot be obtained simply by applying the solvent 35.

Next, when the overlay film 20 is deposited on the solvent 35, the solvent 35 is pushed into fine irregularities depending on the shape of the film 20, and the film thickness is leveled (see FIG. 6B). Furthermore, the fluidity of the thermoplastic resin 10d is improved by rotating the heating roll 36 on the overlay film 20 and heating and pressing, and the solvent 35 is applied to the fine irregularities of the surface 11a of the transparent substrate 11 through the film 20. Is further pressed and cooled after the hot pressing by the heating roll 36 to cure the thermoplastic resin 10d (see FIG. 6C).
And as shown in FIG.6 (d), the 1st light-diffusion layer which consists of the thermoplastic resin 10d which mixed the light-diffusion agent 10b by releasing the overlay film 20 from the hardened 1st light-diffusion layer 37 is shown. 37 is formed in close contact with the transparent substrate 11.
In addition, a state in which the contact surface of the overlay film 20 with the first light diffusion layer 37 is previously processed according to required coating surface characteristics such as a matte surface, an antiglare surface, a mirror surface, etc. is brought into contact with the solvent 35. By performing hot pressing, an arbitrary coating surface such as a mat surface 37a, an antiglare surface, or a mirror surface can be formed on the surface of the first light diffusion layer 37.
Note that a thermoplastic resin may be employed instead of the active energy ray-curable resin as the base material of the second light diffusion layer 33 of the lenticular lens array sheet 31.

  According to the third embodiment, since the thermoplastic resin 10d is employed as the base material of the first light diffusion layer 37 instead of the active energy ray curable resin 10c, the first light having a substantially uniform thickness at a lower cost. The diffusion layer 37 can be manufactured. Moreover, by adopting the thermoplastic resin 10d and hot pressing with the heating roll 36 through the overlay film 20, the fluidity of the thermoplastic resin 10d is improved, and the first light diffusion layer 37 is more tightly connected to the transparent substrate 11. It can be adhered.

In each of the above-described embodiments, an offset Fresnel lens is used as the Fresnel lens 5 of the Fresnel lens sheet 2, but the Fresnel lens is not limited to the one having the above-described configuration. For example, a Fresnel lens having a configuration in which concentric irregularities extend from the center of the Fresnel lens sheet 2 and the optical axis P1 thereof coincides with the center P2 of the light diffusion plate 4 may be adopted.
Moreover, in each embodiment mentioned above, although each light-diffusion layer 10,33,37 is good also as a hard-coat layer which has predetermined | prescribed hardness, as long as the function as the transmissive screens 1 and 30 is not spoiled, it is not necessarily required. The light diffusion layers 10, 33, and 37 do not need to be hard coat layers.

In the above-described embodiments, the manufacturing method of the Fresnel lens sheet 2 and the manufacturing method of the lenticular lens array sheet 31 have been described as the manufacturing method of the light diffusion layer sheet. However, the present invention is not limited to this. .
For example, in the lenticular lens array sheets 3 and 31 according to the present embodiment, a microlens in which a lens array in which a plurality of unit lenses are arranged in a matrix is provided on the incident side of the lenticular lens array 7 (diffuse lens array). It may be an array sheet. Further, for example, on the incident side of the lenticular lens array 7, a first lens array in which a plurality of cylindrical lenses (unit lenses) are arranged substantially in parallel and a first lens array in which a plurality of cylindrical lenses (unit lenses) are arranged in substantially parallel. It may be a cross wrench lens sheet provided with a lens array in which the two lens arrays are arranged on the same plane so that the length directions of the cylindrical lenses intersect each other. Further, for example, the lenticular lens array sheet according to each embodiment is a prism lens array sheet in which a lens array in which a plurality of unit lenses that reflect and diffuse image light are arranged is provided on the incident side of the lenticular lens array. There may be.

It is sectional drawing which shows schematic structure of the transmission type screen by 1st embodiment of this invention. (A)-(c) is a figure which shows the manufacturing method of a Fresnel lens sheet. (A)-(e) is process drawing which shows the method of forming a light-diffusion layer in a transparent substrate in the manufacturing method shown in FIG. It is sectional drawing which shows schematic structure of the transmission type screen by 2nd embodiment. (A)-(e) is process drawing which shows the manufacturing method of a lenticular lens array sheet. (A)-(d) is a figure which shows the manufacturing method of the Fresnel lens sheet by 3rd embodiment.

Explanation of symbols

1, 30 Transmission type screen 2 Fresnel lens sheet 3, 31 Lenticular lens array sheet (diffuse lens array sheet)
4 Light diffusion plate (light diffusion layer)
5 Fresnel lens 7 Lenticular lens array (diffuse lens array)
10, 37 Light diffusing layer, first light diffusing layer 10a Matt surface 11 Transparent substrate (substrate)
20 Overlay film (film)
21 Pressure roll (Pressure means)
32 Adhesive layer (substrate)
33 Second light diffusion layer (light diffusion layer)
36 Heating roll (pressurizing means)

Claims (7)

Applying a thermoplastic resin mixed with a light diffusing agent to one side of the substrate;
A step of adhering a film that has been fixed by performing a matte surface processing, an antiglare surface processing or a mirror surface processing on the surface in contact with the thermoplastic resin ,
Pressurizing the thermoplastic resin with a heating roll through the film and applying heat to improve the fluidity so as to be in close contact with the substrate;
A step of forming a light diffusion layer in which the matte surface, antiglare surface, or mirror surface is transferred with the film by cooling and curing the thermoplastic resin, and closely contacting the substrate. Production method. After the step of forming the light diffusion layer and closely contacting the substrate, the matte surface, antiglare surface or mirror surface is transferred to the light diffusion layer by peeling off the film that has been processed in advance on the surface that contacts the light diffusion layer. The method for producing a light diffusion layer according to claim 1 . The method for producing a light diffusion layer according to claim 1, wherein the film is adhered to the light diffusion layer as a protective layer. In the Fresnel lens sheet in which the first light diffusion layer is arranged on the incident side and the Fresnel lens is arranged on the emission side,
The said 1st light-diffusion layer is manufactured by the manufacturing method of the light-diffusion layer in any one of Claims 1-3 , The manufacturing method of the Fresnel lens sheet characterized by the above-mentioned. In the diffusing lens array sheet in which the diffusing lens array is arranged on the incident side and the second light diffusing layer is arranged on the emitting side,
Said 2nd light-diffusion layer is manufactured by the manufacturing method of the light-diffusion layer in any one of Claims 1-3 , The manufacturing method of the diffusion lens array sheet | seat characterized by the above-mentioned. 6. The method of manufacturing a diffusion lens array sheet according to claim 5 , wherein the substrate is an adhesive layer in close contact with the diffusion lens array. In a transmissive screen in which a Fresnel lens sheet and a diffusing lens array sheet are arranged to face each other,
The Fresnel lens sheet is manufactured by the method for manufacturing a Fresnel lens sheet according to claim 4 , and the diffuser lens array sheet is manufactured by the method for manufacturing a diffuser lens array sheet according to claim 5 or 6. A method for manufacturing a transmission screen.

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