JP5141150B2 - Double-sided shaped sheet manufacturing method, double-sided shaped sheet manufacturing apparatus, double-sided shaped sheet - Google Patents

Description

  The present invention relates to a method for producing a double-sided shaped sheet, a double-sided shaped sheet production apparatus, and a double-sided shaped sheet used for a rear projection display device or the like.

In a rear projection display device or the like, a double-sided shaped sheet in which regular irregular shapes are shaped on both sides, such as a lenticular lens sheet described in Patent Document 1, is used.
Patent Document 1 discloses an example in which a lenticular lens sheet having a lens shape on both sides and further having a black stripe protrusion on the emission side is manufactured by extrusion molding.
On the other hand, Patent Document 2 discloses a photopolymer method using an ultraviolet curable resin or the like as another method for producing a double-sided sheet.
Japanese Patent Laid-Open No. 5-134319 JP 2004-258071 A

In order to increase the size of the display device and to manufacture a larger double-sided shaped sheet, it can be manufactured if a larger mold for extrusion molding can be used. However, since there is a limit to the size of the mold that can be used in the extrusion molding machine, when it is desired to use a mold that is larger than that limit, it is necessary to introduce a new extrusion molding machine itself. Extrusion molding is a manufacturing method suitable for mass production, and when mass production is expected, it is possible to invest in the equipment.
The large display device itself is certainly in demand, but it is not expected to be mass-produced. It is actually difficult to introduce a new extrusion machine only to produce a large double-sided sheet. It is.

  On the other hand, the photopolymer method is suitable for high-mix low-volume production. However, when manufacturing a double-sided molding sheet that molds the lens shape etc. on both sides, after molding one side, the other side is molded, so that the positions of the front and back shapes can be accurately aligned It was difficult. In particular, when trying to manufacture a large double-sided moldable sheet, the mold is stretched due to the temperature and humidity during production, and the single-sided mold is shaped on one side, which is an intermediate product during production. The influence of the expansion and contraction of the sheet is increased, and it is difficult to accurately align the front and back shapes.

  An object of the present invention is to provide a method for producing a double-sided shaped sheet, a double-sided shaped sheet production apparatus, and a double-sided shaped sheet that can accurately match the positions of the front and back shapes even when producing a large sheet. Is to provide.

The present invention solves the above problems by the following means. In addition, in order to make an understanding easy, although the code | symbol corresponding to embodiment of this invention is attached | subjected and demonstrated, it is not limited to this.
According to the first aspect of the present invention, the second unit optical shape (222a) is provided on the other surface of the single-sided shaped sheet (200, 210) in which the first unit optical shape (211a) is regularly arranged on one surface. Is a plate-like molding in which a mold shape (420a) corresponding to the second unit optical shape to be formed is regularly arranged. An application step of applying a photo-curing resin (R) having photo-curing properties on the mold (420), and the other surface of the one-side shaped sheet that is not provided with the first unit optical shape is the photo-curing A placing step of placing on the photo-curing resin so as to face the molding die coated with resin, and a monitoring step of monitoring a relative position in the sheet surface direction of the molding die and the one-side shaped sheet And according to the result of monitoring by the monitoring step, A temperature control step of changing at least one of the temperature of the serial light curing resin and the single-sided embossing sheet, and a curing step of curing the photocurable resin, a double-sided shaping sheet manufacturing method comprising.
Invention of Claim 2 is a manufacturing method of the double-sided shaped sheet | seat of Claim 1, The said mold (420) and the said single-sided shaped sheet | seat (200,210), performing the said monitoring process and the said temperature control process. And a positioning step of performing positioning with a double-sided shaped sheet.
According to a third aspect of the present invention, in the method for manufacturing a double-sided shaped sheet according to the first or second aspect, the monitoring step is provided in the mold (420) separately from the mold shape (420a). Monitoring the relative positions of the mold-side reference shape (420b) and the first reference shape (212) provided separately from the first unit optical shape (211a) on the one-side shaped sheet, Is a method for producing a double-sided shaped sheet.
Invention of Claim 4 is a manufacturing method of the double-sided shaped sheet | seat of any one of Claim 1- Claim 3, The said temperature control process is temperature control which mounts the said shaping | molding die (420). It is a manufacturing method of the double-sided shaping sheet | seat characterized by performing by controlling the heating of the heater provided in the stand (313).
According to a fifth aspect of the present invention, in the method for manufacturing a double-sided shaped sheet according to the fourth aspect of the invention, the temperature adjustment step is performed by individually controlling the plurality of heaters provided on the temperature adjustment table (313). A method for producing a double-sided shaped sheet, characterized in that the temperature is changed for each position of the mold (420).

The invention of claim 6 includes a flat plate-shaped mold (420) in which mold shapes (420a) corresponding to the second unit optical shape (222a) to be formed are regularly arranged, and a first surface on one surface. The other surface of the single-sided shaped sheet (200, 210) in which the unit optical shapes (211a) are regularly arranged is a photo-curing resin (R) having photo-curability applied on the mold. The pressing part (320) that presses the single-sided molding sheet against the molding die in a state of being placed so as to face each other, and the molding die pressed by the pressing part and the single-sided molding sheet A monitoring unit (340, 350) for monitoring a relative position in the in-plane direction of the sheet, and at least one of the mold, the photocurable resin, and the one-side shaped sheet according to a result of monitoring by the monitoring unit Temperature control unit (313, 3) to change one temperature 0), the irradiation unit for irradiating light for curing the photocurable resin (330), an apparatus for manufacturing a double-sided shaping sheet including a (300).
According to a seventh aspect of the present invention, in the double-sided shaped sheet manufacturing apparatus according to the sixth aspect, the mold (420) is operated while the monitoring unit (340, 350) and the temperature control unit (313, 380) are operated. ) And the single-sided shaped sheet (200, 210). An apparatus (300) for producing a double-sided shaped sheet, comprising a positioning unit (360, 370) for positioning the single-sided shaped sheet (200, 210).
The invention according to claim 8 is the double-sided shaped sheet manufacturing apparatus according to claim 6 or 7, wherein the monitoring unit (340, 350) includes the mold shape (420a) and the mold (420). A mold-side reference shape (420b) provided separately, and a first reference shape (212) provided separately from the first unit optical shape (211a) on the one-side shaped sheet (200, 210). It is a double-sided shaped sheet manufacturing apparatus (300) characterized by monitoring the relative position of the sheet.
Invention of Claim 9 is a manufacturing apparatus of the double-sided shaped sheet | seat of any one of Claim 6-8. WHEREIN: The said temperature control part (313,380) is the said mold (420). An apparatus (300) for producing a double-sided shaped sheet, characterized in that the temperature is changed by controlling heating of a heater provided on a temperature control table (313) to be placed.
A tenth aspect of the present invention is the double-sided shaped sheet manufacturing apparatus according to the ninth aspect, wherein the temperature adjustment section (313, 380) individually includes a plurality of heaters provided on the temperature adjustment table (313). It is a double-sided shaped sheet manufacturing apparatus (300) characterized by changing temperature for every position of the said shaping | molding die (420) by controlling to.
The invention of claim 11 includes a base sheet (200), a first unit optical shape (211a) regularly arranged on one surface of the base sheet, and the other surface of the base sheet. The second unit optical shape (222a) regularly arranged corresponding to the first unit optical shape, and the vicinity of the outer periphery of the one surface, provided separately from the first unit optical shape The first reference shape (212) and the outer periphery of the other surface are provided separately from the second unit optical shape, and the first reference shape (212) when viewed from the normal direction of the sheet surface. A second reference shape (223) disposed at a position overlapping with or near the reference shape, and the first unit optical shape is a partial shape having an elliptical cross-sectional shape. Columnar and arranged to form a lenticular lens portion (211), the 2 Unit optical shape, a columnar cross-sectional shape is generally rectangular, two-sided, characterized in that, that the light absorbing portion (222b) is formed on the top, are arranged to form a black stripe portion (222) It is a shaping sheet (20).

According to the present invention, the following effects can be obtained.
(1) The manufacturing method of the present invention includes a monitoring step for monitoring the relative position of the molding die and the single-sided shaped sheet in the sheet surface direction, and the molding die and the photocurable resin according to the result of monitoring by the monitoring step And a temperature adjustment step that changes the temperature of at least one of the single-sided molded sheets, so that the displacement of the front and back due to the difference in the coefficient of thermal expansion is prevented, even when manufacturing a large sheet, A double-sided shaped sheet in which the positions of the front and back shapes are accurately matched can be produced.
In addition, it is not necessary to introduce a large-scale facility, and the above-described effect can be obtained in a large variety of small-quantity production.

(2) Since the manufacturing method of the present invention includes an alignment step of aligning the forming die and the single-sided shaped sheet while performing the monitoring step and the temperature adjustment step, the positions of the front and back shapes are aligned more accurately. be able to.

(3) The monitoring step in the manufacturing method of the present invention includes a mold-side reference shape provided separately from the mold shape in the mold, and a first unit provided separately from the first unit optical shape in the single-sided shaped sheet. Since the relative position with respect to the reference shape is monitored, the positional relationship between the front and back sides can be monitored more accurately, and the positions of the front and back shapes can be more accurately aligned.

(4) Since the temperature adjustment process in the manufacturing method of the present invention is performed by controlling the heating of the heater provided on the temperature adjustment table on which the mold is placed, the mold can be directly heated and the temperature adjustment process is shortened. You can do it in time.

(5) In the temperature control step in the manufacturing method of the present invention, the temperature is changed for each position of the mold by individually controlling a plurality of heaters provided on the temperature control table. The temperature can be finely adjusted and more accurate positioning can be performed.

(6) The manufacturing apparatus of the present invention includes a monitoring unit that monitors the relative position of the molding die pressed by the pressing unit and the single-sided shaped sheet in the sheet surface direction, and a result of monitoring by the monitoring unit. Since it has a temperature control part that changes the temperature of at least one of the mold, photo-curing resin, and single-sided molding sheet, it prevents misalignment due to the difference in thermal expansion coefficient, and the positions of the front and back shapes are accurate. A combined double-sided moldable sheet can be produced.

(7) Since the manufacturing apparatus of the present invention includes an alignment unit that aligns the mold and the single-sided shaped sheet while operating the monitoring unit and the temperature control unit, the position of the front and back shapes can be more accurately determined. Can be matched.

(8) The monitoring unit in the manufacturing apparatus of the present invention includes a mold-side reference shape provided separately from the mold shape in the mold, and a first unit provided separately from the first unit optical shape in the single-sided shaped sheet. Since the relative position with respect to the reference shape is monitored, the positional relationship between the front and back sides can be monitored more accurately, and the positions of the front and back shapes can be more accurately aligned.

(9) Since the temperature control unit in the manufacturing apparatus of the present invention changes the temperature by controlling the heating of the heater provided on the temperature control table on which the mold is placed, the temperature control unit can directly heat the mold. The preparation process can be performed in a short time.

(10) Since the temperature control unit in the manufacturing apparatus of the present invention changes the temperature for each position of the mold by individually controlling a plurality of heaters provided on the temperature control table, the temperature control unit changes according to the position of the mold. The temperature can be finely adjusted and more accurate positioning can be performed.

(11) The double-sided shaped sheet is near the outer periphery of one surface, the first reference shape provided separately from the first unit optical shape, and the outer periphery of the other surface, the second The unit optical shape is provided separately from the unit optical shape and includes a second reference shape that is disposed at a position that overlaps with or near the first reference shape when viewed from the normal direction of the sheet surface. A manufacturing method in which the front and back positions are aligned using the first reference shape and the second reference shape can be applied. Therefore, it can mold | mold one side at a time and can manufacture using the photopolymer method suitable for high-mix low-volume production.

  Even in the case of manufacturing a large sheet, the purpose of accurately aligning the positions of the front and back shapes was achieved by performing the temperature adjustment process, reducing the influence of the coefficient of thermal expansion.

(Embodiment)
FIG. 1 is a diagram illustrating a usage pattern of a diffusion sheet according to the present invention.
FIG. 2 is a partially enlarged view of a cross section of the diffusion sheet taken along arrows SS in FIG.
FIG. 3 is a diagram illustrating a light source side and an observation side of the diffusion sheet. 3A shows the light source side, and FIG. 3B shows the observation side.
1 and 2 show the horizontal direction and the vertical direction in the usage state of the transmission screen 1 by arrows, and the light source side and the observation side are shown. In the following description, unless otherwise specified, the horizontal direction The vertical direction, the light source side, and the observation side refer to directions in the usage state of the transmissive screen 1.
Each of the following drawings including FIG. 1 to FIG. 3 is a diagram schematically shown, and the size and shape of each part are appropriately exaggerated for easy understanding.
In the following description, specific numerical values, shapes, materials, and the like are shown and described, but these can be changed as appropriate.

Furthermore, although words such as a plate, a sheet, and a film are used as general usage in the diffusion sheet 20 and the like described in the present embodiment, these are usually a plate, a sheet, and a film in order of increasing thickness. Are used in this order, and are used in this specification as well. However, since there is no technical meaning in this proper use, the description in the scope of claims is unified and used as a description of a sheet. Accordingly, the terms “sheet”, “plate”, and “film” can be appropriately replaced. For example, the diffusion sheet may be a diffusion plate or a diffusion film.
The transmissive screen 1 according to the present embodiment is used for a rear projection television or the like that uses a single light source such as liquid crystal or DLP (Digital Light Processing) and a multi-tube light source such as a CRT (Cathode Ray Tube) as a projection source. This is a screen to be used, and is formed by superposing a Fresnel lens sheet 10 and a diffusion sheet 20 substantially in parallel in the horizontal and vertical directions.

  The Fresnel lens sheet 10 is a lens sheet in which a Fresnel lens shape is formed on the exit surface, and image light from an image light source (not shown) is substantially parallel (incident at a substantially right angle to the diffusion sheet 20). Let it emit.

The diffusion sheet 20 includes a base sheet layer 200, a first shaping layer 210, and a second shaping layer 220, and is a double-sided shaped sheet in which concave and convex shapes are shaped on both sides.
The base sheet layer 200 is a sheet made of PET (Poly Ethylene Terephthalate) resin having a thickness of 188 μm.
The first shaping layer 210 is a light-curing resin that is integrally bonded to the light source side of the base sheet layer 200, has a lenticular lens portion 211, and a first reference shape 212, and is cured by ultraviolet rays. It is formed of a certain ultraviolet curable resin. The material for forming the first shaping layer 210 is not limited to an ultraviolet curable resin, but a photocurable resin such as an ionizing radiation curable resin that is cured by other ionizing radiation, for example, acrylate, epoxy acrylate, silicon acrylate, A photocrosslinking resin mainly composed of a polyfunctional monomer such as siloxane can be used. Here, the ionizing radiation means an electromagnetic wave or a charged particle beam having an energy quantum capable of polymerizing and crosslinking molecules.

The lenticular lens unit 211 constitutes a lenticular lens in which unit optical shapes 211a protruding toward the light source are arranged at equal intervals in the horizontal direction at a pitch P = 254 μm. The unit optical shape 211a has a partially elliptical cross-sectional shape shown in FIG. 2, and extends linearly in the vertical direction with this cross-sectional shape. Therefore, the surface shape of the unit optical shape 211a is a partial shape of an elliptic cylinder.
The first reference shape 212 is formed in the vicinity of both ends in the horizontal direction of the first shaping layer 210 and protrudes toward the light source in the region where the lenticular lens portion 211 is not formed. In the first reference shape 212, the cross-sectional shape shown in FIG. 2 is an isosceles triangle, and this cross-sectional shape extends linearly in the vertical direction.

The second shaping layer 220 is integrally bonded to the observation side of the base sheet layer 200, and has an emission part 221, a black stripe (hereinafter referred to as BS) part 222, and a second reference shape 223. And, like the first shaping layer 210, it is formed by curing an ultraviolet curable resin.
The emission unit 221 is provided near the focal point of the unit optical shape 211a of the lenticular lens unit 211, is a plane parallel to the sheet surface, and extends linearly in the vertical direction. Therefore, the emission part 221 is formed at a position overlapping the vicinity of the apex of the unit optical shape 211a of the lenticular lens part 211 when viewed from the normal direction to the sheet surface of the diffusion sheet 20. In addition, although the output part 221 of this embodiment showed the example which is a plane, it is good also as a lens shape which protruded to the observation side, for example. Here, the sheet surface indicates a surface defined as a planar direction of the diffusion sheet 20 when viewed as the entire diffusion sheet 20, and is a surface parallel to the base sheet layer 200 in this embodiment. , And the same definition in the description of the claims and the following description.

  The BS portion 222 is formed by arranging unit optical shapes 222a that extend in a straight line in the vertical direction while the cross-sectional shape shown in FIG. The BS unit 222 is a non-emission unit through which light collected by the unit optical shape 211 a of the lenticular lens unit 211 does not pass, and is provided at a position sandwiched by the emission unit 221. The horizontal width B of the unit optical shape 222a is 150 μm, and the amount of protrusion of the unit optical shape 222a to the observation side (distance from the emitting portion 221 to the observation side surface of the unit optical shape 222a) D = 50 μm. . The BS unit 222 has a light absorbing unit 222b on the most observation side. The light absorption part 222b is formed of black ink having light absorption.

  The second reference shape 223 is formed in the vicinity of both ends in the horizontal direction of the second shaping layer 220 and protrudes toward the light source in the region where the BS portion 222 is not formed. The second reference shape 223 has an isosceles triangle cross-sectional shape shown in FIG. 2, and extends linearly in the vertical direction with this cross-sectional shape. The second reference shape 223 has the same cross-sectional shape as the first reference shape 212, and is formed at a position overlapping the first reference shape 212 when viewed from the normal direction to the sheet surface. Yes.

Next, the manufacturing apparatus 300 used for manufacturing the diffusion sheet 20 of the present embodiment will be described.
FIG. 4 is a perspective view showing a diffusion sheet manufacturing apparatus. FIG. 4A shows the whole, and FIG. 4B shows only the main part of the manufacturing apparatus for easy viewing of the drawing. FIG. 4 shows XYZ orthogonal coordinates in which the X-axis is provided in the longitudinal direction of the apparatus, the Y-axis in the width direction, and the Z-axis in the height direction, and this coordinate system is used as appropriate in the following description of the manufacturing apparatus. I will do it. The diffusion sheet 20 of this embodiment is manufactured by the manufacturing apparatus 300 shown in FIG. 4 in a state where the horizontal direction is the X direction and the vertical direction is the Y direction.
The manufacturing apparatus 300 includes a mold conveying unit 310, a roll unit 320, a UV irradiation unit 330, a first monitoring unit 340, a second monitoring unit 350, an alignment unit 360, a tension unit 370, And a computer 380.

The mold conveying unit 310 includes a base 311, a moving table 312, a temperature adjusting table 313, and a rail 314.
The base portion 311 includes a flat portion 311a and frame portions 311b that are formed high in the Z plus direction at both ends in the Y-axis direction of the flat portion 311a.
The moving table 312 is a substantially plate-like member arranged so as to be movable in the X direction on the flat part 311a sandwiched between the frame parts 311b. The moving table 312 moves in the X direction on the flat portion 311a by a moving mechanism (not shown).
The temperature adjustment table 313 is fixed on the movable table 312, and a plurality of heaters and temperature sensors (not shown) are arranged therein, and a temperature adjustment unit is formed together with a computer 380 to control these, which will be described later. ing. Molding molds 410 (see FIG. 5A) and 420 for molding the diffusion sheet 20 are detachably mounted on the temperature control table 313.
The rail 314 is located on the Z plus side of the frame 311b on the X plus side relative to the central portion in the X direction, and includes a roll unit 320, a UV irradiation unit 330, which will be described later, It is a rail that supports the first monitoring unit 340, the second monitoring unit 350, and the alignment unit 360 so as to be movable in the X direction.

The roll part 320 includes a support part 321 and a roller 322, and is arranged near the center of the base part 311 in the X direction.
The support part 321 is on the Z plus side of the mold conveying part 310, is supported by the two frame parts 311b, and is arranged between the two frame parts 311b.
The roller 322 is rotatably supported by the support portion 321 via a lifting mechanism (not shown). The roller 322 can be moved in the Z direction by an elevating mechanism.

The UV irradiation unit 330 includes a support unit 331 and a light source unit 332, and is disposed near the center of the base unit 311 in the X direction and on the X plus side of the roll unit 320.
The support portion 331 is on the Z plus side of the mold conveying unit 310, is supported by the two frame portions 311b, and is disposed between the two frame portions 311b.
The light source unit 332 is supported by the support unit 331 and emits UV (ultraviolet light) to irradiate the entire ultraviolet curable resin applied on the molds 410 and 420 with UV.

The first monitoring unit 340 includes a support unit 341, a first camera group 342, and a spot UV irradiation unit 343, which is on the X plus side from the vicinity of the center in the X direction of the base unit 311, and UV It is arranged on the X plus side from the irradiation unit 330.
The support part 341 is on the Z plus side of the mold conveying part 310 and is supported by the rails 314 on the two frame parts 311b so as to be movable in the X direction, and is disposed between the two frame parts 311b. ing.
The first camera group 342 is a plurality of cameras that are supported by the support unit 341 and monitor the surfaces of the molding dies 410 and 420 placed on the temperature control table 313 and the surface of the diffusion sheet 20 being molded. In the first camera group 342 of the present embodiment, three cameras are arranged at equal intervals in the Y direction.
The spot UV irradiation unit 343 is supported by the support unit 341 and is a partial irradiation unit that performs UV irradiation on a limited small range of the ultraviolet curable resin applied on the molds 410 and 420. Three spot UV irradiation units 343 of the present embodiment are arranged at equal intervals in the Y direction.

The second monitoring unit 350 includes a support unit 351 and a second camera group 352, and is disposed near the X plus side end of the base unit 311 in the X direction.
The support portion 351 is located on the Z plus side of the mold conveying unit 310 and is supported by the rails 314 on the two frame portions 311b so as to be movable in the X direction, and is disposed between the two frame portions 311b. ing.
The second camera group 352 is a plurality of cameras that are supported by the support unit 351 and monitor the surfaces of the molding dies 410 and 420 placed on the temperature control table 313 and the surface of the diffusion sheet 20 in the middle of molding. In the second camera group 352 of the present embodiment, three cameras are arranged at equal intervals in the Y direction.
The first camera group 342 shown above monitors the surfaces of the molds 410 and 420 and the vicinity of the X minus side end of the diffusion sheet 20 in the middle of molding, and the second camera group 352 includes a mold. The surface of 410 and 420 and the vicinity of the end portion on the X plus side of the diffusion sheet 20 in the middle of molding are monitored.

The alignment unit 360 includes a support unit 361, an elevating mechanism 362, and an XY drive mechanism 363, and is on the X plus side in the X direction of the base unit 311, and includes the first monitoring unit 340 and the second monitoring unit. It is arranged between the part 350.
The support part 361 is located on the Z plus side of the mold conveying part 310, is supported by the rails 314 on the two frame parts 311b so as to be movable in the X direction, and is arranged between the two frame parts 311b. ing.
The elevating mechanism 362 is a mechanism that is supported by the support portion 361 and supports the XY drive mechanism 363 so as to be movable in the Z direction. The lifting mechanism 362 of this embodiment moves the XY drive mechanism 363 in the Z direction by an air cylinder.
The XY drive mechanism 363 is in contact with the diffusion sheet 20 (first shaping layer 210) in the middle of molding, and moves the diffusion sheet 20 slightly, so that the diffusion sheet 20 in the middle of molding and the molding die 420 are relative to each other. This is a mechanism for finely adjusting the specific position. In the XY drive mechanism 363, the contact portion 363a with the diffusion sheet 20 is formed of rubber, and movement in the X direction and the Y direction and rotation around the Z axis are performed by a built-in motor (not shown). Each can be executed independently.

The tension part (extension part) 370 grips the X plus side end part of the first shaping layer 210 and the base sheet layer 200 which are part of the diffusion sheet 20 in the middle of molding, and pulls it in the X plus direction. The first shaping layer 210 and the base sheet layer 200 are stretched portions. In the present embodiment, the tension part 370 is provided with three portions for gripping the first shaping layer 210 along the Y direction, and the amount of tension is independently controlled by the computer 380 at each position. The first shaping layer 210 and the base sheet layer 200 can be pulled in the X plus direction with different pulling amounts for each position of the shaping layer 210 in the Y direction. The direction in which the tensile portion 370 pulls the first shaping layer 210 and the base sheet layer 200 is a direction orthogonal to the direction in which the unit optical shape 211a formed in the first shaping layer 210 extends, that is, It is the direction (horizontal direction) in which the unit optical shapes 211a are arranged.
The pulling portion 370 of the present embodiment grips the first shaping layer 210 using a chuck mechanism driven by air pressure and obtains a pulling force by an air cylinder (not shown), but uses a chuck mechanism using a screw. May be gripped, or a pulling force may be obtained using a motor.

  The computer 380 is connected to the manufacturing apparatus 300, and each part of the manufacturing apparatus, specifically, the mold transfer unit 310, the roll unit 320, the UV irradiation unit 330, the first monitoring unit 340, and the second monitoring unit 340 This is a control unit that comprehensively controls the monitoring unit 350, the alignment unit 360, and the pulling unit 370. The computer 380 of the present embodiment uses a general-purpose computer, and a program necessary for controlling the manufacturing apparatus 300 is installed. By executing this program, the operation of the hardware of each unit is controlled. Is done.

FIGS. 5-1 and 5-2 are diagrams schematically illustrating a manufacturing process of the diffusion sheet.
Hereinafter, the manufacturing method of the diffusion sheet 20 will be described with reference to FIGS. For easy understanding, each part of the diffusion sheet 20 in the manufacturing process will be described with reference to FIGS. 5A and 5B with the same reference numerals as those of the above-described completed diffusion sheet 20. I do. Further, unless otherwise specified, various operations in the manufacturing process described below are performed under the control of the computer 380.

  First, a molding die 410 that is a die having a substantially flat plate shape as a whole is prepared. On one surface of the mold 410, a mold shape 410 a corresponding to the unit optical shape 211 a of the lenticular lens unit 211 and a mold shape 410 b corresponding to the first reference shape 212 are formed. The mold shape 410b corresponding to the first reference shape 212 is provided at both ends in the X direction of the mold 410 with a predetermined interval. The mold 410 is placed on the temperature control table 313 with the surface on which the mold shapes 410a and 410b are formed facing upward (Z plus side). In FIGS. 5A and 5B, the temperature control table 313 is omitted. An UV curable resin R is applied to the upper surface of the molding die 410 placed on the temperature control table 313 (first application step), and a sheet 200 made of PET resin having a thickness of 188 μm for forming the base sheet layer 200. Is further placed on the ultraviolet curable resin R (first placing step) (FIG. 5-1 (a)). These processes are performed on the X minus side of the manufacturing apparatus 300.

  After the sheet 200 made of PET resin is placed, the roller 322 of the roll unit 320 is lowered by a predetermined amount, and the moving table 312 of the mold conveying unit 310 moves in the X plus direction, while the roller 322 is the sheet 200 made of PET resin. Rolling up, the UV curable resin R is uniformly extended between the PET resin sheet 200 and the molding die 410 (FIG. 5-1 (b)).

After the ultraviolet curable resin R is uniformly extended, the moving table 312 of the mold conveying unit 310 moves in the X plus direction and reaches the UV irradiation unit 330. The light source unit 332 emits ultraviolet rays, passes through the sheet 200 made of PET resin, and irradiates the ultraviolet curable resin R with ultraviolet rays for a predetermined time (first curing step) (FIG. 5-1 (c)).
After the ultraviolet curable resin R is cured, the moving table 312 of the mold conveying unit 310 moves in the X minus direction and is removed from the mold 410, whereby the first shaping layer 210 joined to the base sheet layer 200 is obtained. Is completed (FIG. 5-1 (d)). The removal from the mold 410 is performed manually by the operator, but may be mechanized.

When the first shaping layer 210 is completed, the molding die 410 is removed from the temperature control table 313, and the molding die 420 is placed on the temperature control table 313 instead of the molding die 410. The mold 420 is a mold having a substantially flat plate shape as a whole, and has a mold shape 420 a corresponding to the unit optical shape 222 a of the BS portion 222 and a mold corresponding to the second reference shape 223 on one surface. A side reference shape 420b is formed. The mold side reference shape 420b corresponding to the second reference shape 223 is provided at both ends in the X direction of the forming die 420 with a predetermined interval, and the interval is the first interval provided in the forming die 410. It is created so as to be equal to the interval of the mold shape 410 b corresponding to the reference shape 212.
The mold 420 is placed on the temperature control table 313 with the surface on which the mold shape 420a and the mold-side reference shape 420b are formed facing upward (Z plus side). The ultraviolet curable resin R is applied to the upper surface of the mold 420 placed on the temperature control table 313 (second application step), and the first shaping layer 210 and the base sheet layer 200 prepared above are applied. Then, the substrate sheet layer 200 is placed on the ultraviolet curable resin R so as to be in contact with the ultraviolet curable resin R (second placing step) (FIG. 5-2 (e)).

  After the first shaping layer 210 and the base sheet layer 200 are placed on the ultraviolet curable resin R, the roller 322 of the roll unit 320 is lowered by a predetermined amount, and the moving table 312 of the mold conveying unit 310 is X plus. While moving in the direction, the roller 322 rolls on the first shaping layer 210 and uniformly extends the ultraviolet curable resin R between the base sheet layer 200 and the mold 420 (FIG. 5-2 (f)). ).

After the ultraviolet curable resin R is uniformly extended by the roll unit 320, the moving table 312 of the mold conveying unit 310 moves in the X plus direction and moves to the position shown in FIG. In this state, the mold 420 is heated to a temperature suitable for ultraviolet curing of the ultraviolet curable resin R by a heater built in the temperature control table 313.
When the ultraviolet curable resin R is cured by being irradiated with ultraviolet rays, there are heat generation due to latent heat of the resin generated when the ultraviolet curable resin R is cured and heat generation caused by ultraviolet irradiation. Therefore, when the ultraviolet curable resin R is cured with ultraviolet rays at room temperature, the mold 420, the base sheet layer 200, and the first shaping layer 210 are thermally expanded by these heats. Since the mold 420, the base sheet layer 200, and the first mold layer 210 have different coefficients of thermal expansion, the positions of the first mold layer 210 and the second mold layer 220 after molding. This causes a shift and a pitch shift. This positional deviation and pitch deviation become more prominent as the size of the diffusion sheet 20 increases.
Therefore, in the present embodiment, the mold 420 is heated to approximately 45 ° C. by a heater built in the temperature control table 313 (first temperature control process). The state of heating by the temperature control table 313 is detected by a temperature sensor and monitored by a computer 380.

  After being heated to a predetermined temperature (approximately 45 ° C. in the present embodiment) by the temperature adjustment table 313, the first camera group 342 and the second camera group 352 provide a position that becomes the second reference shape 223, that is, The mold side reference shape 420b and the first reference shape 212 are photographed. The photographing results obtained by the first camera group 342 and the second camera group 352 are sent to the computer 380 for image processing, and the relative positions of the mold side reference shape 420b and the first reference shape 212 are relative to each other. The positional relationship is accurately grasped (monitoring process).

FIG. 6 is a diagram illustrating an example of an image captured by the first camera group and the second camera group.
The first camera group 342 and the second camera group 352 of the present embodiment each have three cameras in the Y direction. FIG. 6 shows a camera arranged in the center in the Y direction. Photographed images are omitted. An image P1 shown in FIG. 6 shows an image taken by a camera provided on the Y minus side of the first camera group 342, and an image P2 is on the Y plus side of the first camera group 342. An image photographed by the provided camera is shown, an image P3 represents an image photographed by a camera provided on the Y minus side in the second camera group 352, and an image P4 represents the second camera group 352. An image taken by a camera provided on the Y plus side is shown. In FIG. 6, the first reference shape 212 is indicated by a solid line, the mold-side reference shape 420 b corresponding to the second reference shape 223 is indicated by a broken line, and an image in which only the solid line is shown is an overlap between the solid line and the broken line. To do.

  After grasping the relative positional relationship between the position of the mold-side reference shape 420b and the position of the first reference shape 212, according to the result, the relative positional relationship between the two becomes a desired relationship, The following second temperature adjustment step and alignment step are performed (FIG. 5-2 (g)).

(Second temperature control process)
The second temperature adjustment step is a more precise control of the heating of the mold 420 performed in the first temperature adjustment step described above, and the heat of the first shaping layer 210 and the base sheet layer 200. This is a step of correcting misalignment between the two caused by the difference between the expansion coefficient and the thermal expansion coefficient of the mold 420.

  For example, when the interval B of the first reference shape 212 (solid line) is narrower than the interval A of the mold-side reference shape 420b (broken line) as shown in FIG. Further heating is performed. The mold 420 is made of metal and has a smaller thermal expansion coefficient than the first shaping layer 210 obtained by curing the ultraviolet curable resin R. Therefore, by raising the temperature, the first shaping layer 210 expands more than the mold 420, and the interval B of the first reference shape 212 (solid line) and the interval A of the mold side reference shape 420b (broken line) And the arrangement pitch of the unit optical shape 211a after molding and the unit optical shape 222a can be matched. When the relationship between the solid line and the broken line is opposite to that shown in FIG. 6A, it is preferable to suppress the heating by the temperature control table 313 and lower the temperature. Further, when the relationship between the thermal expansion coefficients of the material forming the first shaping layer 210 and the material forming the mold 420 is the reverse of the above example, the control corresponding to that may be performed.

(Positioning process)
The alignment step refers to the first shaping layer 210 by physically applying a force to the first shaping layer 210 and the base sheet layer 200 to change the position and the stretched state. This is a step of matching the positions of the shaped shape with the mold shape 420a and the mold-side reference shape 420b formed in the mold 420. The alignment step includes a first alignment step in which the first shaping layer 210 and the base sheet layer 200 are moved as a whole using the alignment portion 360, and a first shaping layer using the tension portion 370. 210 and the second alignment step of changing the expansion / contraction state so as to correct the distortion of the base sheet layer 200.

  In the first alignment process, first, the elevating mechanism 362 moves the XY drive mechanism 363 to the Z minus side to bring the contact portion 363a of the XY drive mechanism 363 into contact with the first shaping layer 210. Then, the XY drive mechanism 363 is driven based on the images photographed by the first camera group 342 and the second camera group 352 to move the first shaping layer 210 and the base sheet layer 200 as a whole. The positions of the shape molded on the first molding layer 210 and the mold shape 420a and the mold-side reference shape 420b formed on the mold 420 are aligned.

  Before the second alignment step, the first alignment step described above is performed in advance, so that the mold-side reference shape 420b and the first reference shape 420b at the end on the X minus side shown in the images P1 and P2 in FIG. One reference shape 212 is made coincident. In the second alignment step, the spot UV irradiation unit 343 partially irradiates ultraviolet rays only on the portion that becomes the second reference shape 223 at the end portion on the X minus side. In this embodiment, ultraviolet rays are irradiated to three locations, and the second reference shape 223 of the second shaping layer 220 is cured at the three irradiated locations. Next, the X shaping | molding side edge part of the 1st shaping layer 210 and the base material sheet layer 200 is hold | gripped with the tension | pulling part 370, and it pulls to a X plus direction (extension | stretching process).

For example, in the state shown in FIG. 6B after the first alignment step, the first shaping layer 210 and the base sheet layer 200 are distorted in the XY plane. It can be said. This is a phenomenon that tends to occur when in-plane anisotropy exists in the sheet made of PET resin used for the base sheet layer 200. In this case, the amount of tension by the Y plus side tension portion 370 is increased, and the amount of tension by the Y minus side tension portion 370 is reduced, thereby reducing the first shaping layer 210 and the base sheet layer 200 in the XY plane. Correct the distortion.
When the second shaping layer 220 is formed while distortion occurs in the XY plane of the first shaping layer 210 and the base sheet layer 200, the unit optical shape of the lenticular lens portion 211 of the completed diffusion sheet 20 There is a shift in the arrangement direction (the horizontal direction as the diffusion sheet 20 and the X direction in the manufacturing process) between the 211a and the unit optical shape 222a of the BS unit 222. However, by setting the direction in which the pulling portion 370 pulls the first shaping layer 210 and the base sheet layer 200 as the X direction, the first shaping layer 210 and the base are arranged in the direction in which the unit optical shapes 211a are arranged. The material sheet layer 200 is pulled. Therefore, the distortion can be effectively corrected with a small amount of tension, and the diffusion sheet 20 can be produced without any deviation between the front and back surfaces of the diffusion sheet 20.

  The second temperature adjustment step and the alignment step described above are performed as appropriate (repeated several times in some cases) according to the images taken by the first camera group 342 and the second camera group 352, and the second temperature adjustment step and the alignment step are performed in the XY plane. The position of one reference shape 212 and the position of the mold-side reference shape 420b are made to coincide at both ends in the X direction, or the amount of displacement is within an allowable range.

  After performing the second temperature adjustment process and the alignment process, the moving table 312 of the mold conveying unit 310 moves in the X minus direction and reaches the UV irradiation unit 330. The light source unit 332 emits ultraviolet rays, passes through the first shaping layer 210 and the base sheet layer 200, and irradiates the ultraviolet curable resin R with ultraviolet rays for a predetermined time (second curing step) (FIG. 5). 2 (h)).

After the ultraviolet curable resin R is cured, the moving table 312 of the mold conveying unit 310 moves in the X minus direction and is removed from the mold 420, whereby the first shaping layer 210, the base sheet layer 200, and the second The formation with the shaping layer 220 is completed, and the shape of the diffusion sheet 20 is completed (FIG. 5-2 (i)). The removal from the mold 420 is performed manually by the operator, but may be mechanized.
Finally, a black ink having light absorptivity is printed on the apex portion of the unit optical shape 222a to form the light absorbing portion 222b, and the diffusion sheet 20 is completed.

As described above, the emission part 221 is formed at a position overlapping the apex of the unit optical shape 211a of the lenticular lens part 211 when viewed from the normal direction to the sheet surface of the diffusion sheet 20, and the BS part 222. Is a non-emission part through which the light collected by the unit optical shape 211 a of the lenticular lens part 211 does not pass, and is provided at a position sandwiched between the emission parts 221. As a result, the BS unit 222 can exhibit the effect of increasing the contrast of the image by absorbing unnecessary external light and stray light without blocking the image light. However, if the front and back positional relationship of the diffusion sheet 20 is shifted, the light collected by the unit optical shape 211a of the lenticular lens unit 211 is blocked by the BS unit 222, and the displayed image is deteriorated.
Therefore, in the present embodiment described above, the second temperature adjustment process is performed in accordance with the images captured by the first camera group 342 and the second camera group 352. Thereby, it is possible to correct a positional shift such as a shift in the arrangement pitch between the front and back surfaces caused by the difference in thermal expansion coefficient, and the positions of the front and back shapes can be accurately matched. Accordingly, the diffusion sheet 20 manufactured by the manufacturing method of the present embodiment has the same position of the front and back shapes, and absorbs unnecessary external light and stray light without blocking the image light, thereby improving the contrast of the image. High picture can be displayed.
In addition, since the strain is corrected using the pulling portion 370, the positions of the front and back shapes can be more accurately matched.

(Deformation)
The present invention is not limited to the embodiment described above, and various modifications and changes are possible, and these are also within the scope of the present invention.
(1) In the present embodiment, an example is shown in which the first shaping layer 210 in which the lenticular lens portion 211 is formed is formed first, and then the second shaping layer 220 in which the BS portion 222 is formed is subsequently formed. However, the present invention is not limited to this. For example, the second shaping layer 220 may be formed first. Moreover, as long as the shape is formed on both sides, the shape to be formed may be any form. For example, a so-called fly-eye lens in which a number of fine unit lens shapes are arranged in a two-dimensional direction, a Fresnel lens, or a prism sheet in which a number of triangular prism shapes (prism shapes) are arranged It may be a shape.

(2) In the present embodiment, the first reference shape 212 and the second reference shape 223 show examples in which the cross-sectional shape extends linearly in the vertical direction while maintaining an isosceles triangle. For example, the cross-sectional shape may be a rectangle or a semicircular shape. Further, the cross-sectional shape may not be extended in one direction with the same cross-sectional shape. For example, a reference shape is formed only in a portion corresponding to each camera of the first camera group 342 and the second camera group 352. May be.

(3) In this embodiment, although the 1st temperature control process and the 2nd temperature control process showed the example performed by heating the temperature control stand 313, it is not restricted to this, For example, of the manufacturing apparatus 300 You may perform a 1st temperature control process and a 2nd temperature control process by adjusting the temperature in a temperature-controlled room as a structure which puts all or one part in a temperature-controlled room.

(4) In the present embodiment, the first temperature adjustment step and the second temperature adjustment step are performed by uniformly heating the entire temperature adjustment table 313. However, the present invention is not limited to this. A plurality of heaters built in the adjusting table 313 may be controlled independently to change the temperature depending on the position of the temperature adjusting table 313. Further, cooling control may be added by providing a cooling water circulation structure in the temperature control table 313.

(5) In the present embodiment, an example in which the temperature adjustment process and the alignment process are performed by observing the first reference shape 212 and the mold-side reference shape 420b has been described. Without providing the shape, the temperature adjustment step and the alignment step may be performed by observing the optical shape on one side and the mold shape corresponding to the optical shape to be formed on the other side.

(6) In the present embodiment, the first reference shape 212 and the mold-side reference shape 420b are provided at both ends in the horizontal direction (X direction). Further, it may be provided at both ends in the direction (Y direction), and this portion may be monitored.
In addition, although this embodiment and modification can also be used in combination as appropriate, detailed description is abbreviate | omitted. Further, the present invention is not limited by the embodiments described above.

It is a figure explaining the usage pattern of the diffusion sheet by this invention. It is the elements on larger scale of the cross section which cut | disconnected the diffusion sheet by arrow SS in FIG. It is a figure which shows the light source side and observation side of a diffusion sheet. It is a perspective view which shows the manufacturing apparatus of a diffusion sheet. It is the figure which showed the manufacturing process of the diffusion sheet typically. It is the figure which showed the manufacturing process of the diffusion sheet typically. It is a figure which shows the example of the image image | photographed with the 1st camera group and the 2nd camera group.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Transmission type screen 10 Fresnel lens sheet 20 Diffusion sheet 200 Base material sheet layer 210 1st shaping | molding layer 211 Lenticular lens part 211a Unit optical shape 212 1st reference | standard shape 220 2nd shaping | molding layer 221 Output part 222 Black stripe (BS) unit 223 second reference shape 300 manufacturing apparatus 310 mold conveying unit 311 base unit 312 moving table 313 temperature control table 314 rail 320 roll unit 321 support unit 322 roller 330 UV irradiation unit 331 support unit 332 light source unit 340 first 1 monitoring section 341 supporting section 342 first camera group 343 spot UV irradiation section 350 second monitoring section 351 supporting section 352 second camera group 360 positioning section 361 supporting section 362 lifting mechanism 363 XY driving mechanism 370 pulling section 380 Compu 410, 420 Mold 410a, 410b, 420a Mold shape 420b Mold side reference shape

Claims (11)

A production method for producing a double-sided shaped sheet by shaping the second unit optical shape on the other side of the single-sided shaped sheet in which the first unit optical shape is regularly arranged on one side,
An application step of applying a photocurable resin having photocurability onto a flat plate-shaped mold in which mold shapes corresponding to the second unit optical shapes to be formed are regularly arranged;
A placing step of placing the other surface of the single-sided shaping sheet on the photo-curing resin so that the other surface not provided with the first unit optical shape is opposed to the molding die coated with the photo-curing resin;
A monitoring step of monitoring a relative position of the molding die and the one-side shaped sheet in the sheet surface direction;
A temperature adjustment step of changing the temperature of at least one of the mold, the photocurable resin, and the single-sided shaped sheet according to the result of monitoring by the monitoring step;
A curing step of curing the photocurable resin;
A method for producing a double-sided shaped sheet. In the manufacturing method of the double-sided shaped sheet | seat of Claim 1,
Providing an alignment step of aligning the mold and the single-sided shaped sheet while performing the monitoring step and the temperature adjustment step;
A method for producing a double-sided shaped sheet characterized by the above. In the manufacturing method of the double-sided shaped sheet | seat of Claim 1 or Claim 2,
The monitoring step includes: a mold side reference shape provided separately from the mold shape in the mold; and a first reference shape provided separately from the first unit optical shape in the one-side shaped sheet. Monitoring the relative position,
A method for producing a double-sided shaped sheet characterized by the above. In the manufacturing method of the double-sided shaped sheet | seat of any one of Claim 1- Claim 3,
The temperature control step is performed by controlling heating of a heater provided on a temperature control table on which the mold is placed;
A method for producing a double-sided shaped sheet characterized by the above. In the manufacturing method of the double-sided shaped sheet | seat of Claim 4,
In the temperature adjustment step, the temperature is changed for each position of the mold by individually controlling the plurality of heaters provided on the temperature adjustment table.
A method for producing a double-sided shaped sheet characterized by the above. A plate-shaped mold in which mold shapes corresponding to the second unit optical shapes to be formed are regularly arranged;
The other surface of the single-sided shaped sheet in which the first unit optical shapes are regularly arranged on one surface is opposed to the photocurable resin having photocurability applied on the mold. A pressing part that presses the single-sided molding sheet against the molding die in a loaded state;
A monitoring unit for monitoring a relative position in the sheet surface direction between the molding die pressed by the pressing unit and the one-side shaped sheet;
A temperature control unit that changes the temperature of at least one of the mold, the photocurable resin, and the single-sided shaped sheet according to the result of monitoring by the monitoring unit;
An irradiation unit for irradiating the photocurable resin with light for curing;
An apparatus for producing a double-sided mold sheet. In the manufacturing apparatus of the double-sided shaped sheet | seat of Claim 6,
A positioning unit that performs positioning of the mold and the single-sided molding sheet while operating the monitoring unit and the temperature control unit;
An apparatus for producing a double-sided shaped sheet. In the manufacturing apparatus of the double-sided shaped sheet | seat of Claim 6 or Claim 7,
The monitoring unit includes: a mold side reference shape provided separately from the mold shape in the mold; and a first reference shape provided separately from the first unit optical shape in the one-side shaped sheet. Monitoring the relative position,
An apparatus for producing a double-sided shaped sheet. In the manufacturing apparatus of the double-sided shaped sheet | seat of any one of Claim 6 to Claim 8,
The temperature control unit changes the temperature by controlling heating of a heater provided on a temperature control table on which the mold is placed,
An apparatus for producing a double-sided shaped sheet. In the manufacturing apparatus of the double-sided shaped sheet | seat of Claim 9,
The temperature control unit changes the temperature for each position of the molding die by individually controlling the plurality of heaters provided on the temperature control table,
An apparatus for producing a double-sided shaped sheet. A base sheet;
A first unit optical shape regularly arranged on one surface of the base sheet;
A second unit optical shape regularly arranged corresponding to the first unit optical shape on the other surface of the base sheet;
A first reference shape provided near the outer periphery of the one surface and separately from the first unit optical shape;
Near the outer periphery of the other surface, which is provided separately from the second unit optical shape, and is located at or near the first reference shape when viewed from the normal direction of the sheet surface A second reference shape disposed at a position;
Equipped with a,
The first unit optical shape is a columnar shape whose cross-sectional shape is a part of an ellipse, and is arranged to form a lenticular lens portion,
The unit optical shape of 2 is a columnar shape having a substantially rectangular cross-sectional shape, a light absorbing portion is formed at the top, and arranged to form a black stripe portion,
A double-sided shaped sheet characterized by

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