JPH10221781A - Device and method for manufacturing film screen - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent the horizontal movement and/or thermal behavior of a base film from occurring and to enhance the positional accuracy of an optical element formed on both surfaces of the base film by fixing first and second molding rolls and the base film when the base film is moved to the second molding roll from the first molding roll. SOLUTION: Rings with pins 12b provided with many pins 12b-1 are inserted and fixed to the small-diameter parts 12a of both end parts of the second metallic mold roll 12. Then, the base film 101 is moved to the roll 12 from the first metallic mold roll 11. At this time, the metallic pins 12b-1 of the rings 12b fixed to both ends of the roll 12 pierce through the film 101 and they are stuck in the receiving ring made of rubber 11c of the roll 11. Thus, since the roll 11, the film 101 and the roll 12 are integrated and positioned, the film 101 does not shrink caused by the horizontal movement and the thermal behavior with respect to the rolls 11 and 12.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a film screen manufacturing apparatus and method for forming optical elements on both sides of a base film.

[0002]

2. Description of the Related Art FIG. 6 is a view showing an example of a conventional film screen manufacturing apparatus (Japanese Patent Laid-Open No. 3-64701). The first mold roll 1 is a roll having a light entrance side lens mold formed on the surface thereof. The second mold roll 2 is a roll having a light emitting side lens mold formed on a surface thereof. The first coating unit 3 includes a first mold roll 1 and a base film 10.
This is a portion where the ultraviolet curable resin 102A is applied between the light-receiving surface 1 and the light-entering surface side. The second coating part 4 is a part for applying the ultraviolet curable resin 103A between the second mold roll 2 and the light emitting surface side of the base film 101.

[0003] The first and second ultraviolet lamps 5 and 6 are light sources for irradiating the ultraviolet curing resins 102A and 103A in a softened state with ultraviolet rays for curing. The printing unit 7 includes a non-light-emitting portion on the light-emitting side of the formed film screen 100,
This is a portion for forming a light absorbing portion (black stripe) BS or the like. R1 and R2 are rubber rolls, R3
Is a take-up roll, and R4 is a guide roll.

The ultraviolet curable resin 102A is applied between the base film 101 and the first mold roll 1 by the first coating unit 3 and is sealed on the right side of the first mold roll 1 by the base film 101. The part is cured by irradiation of the first ultraviolet lamp 5. Accordingly, the lens mold of the first mold roll 1 is transferred to the light entrance side of the base film 101, and the light entrance side lens portion 102 is formed.

Similarly, the ultraviolet curable resin 103A is applied between the base film 101 and the second mold roll 2 by the second coating unit 4 and is sealed by the base film 101. Is cured by irradiation of the second ultraviolet lamp 6. Accordingly, the lens mold of the second mold roll 2 is transferred to the light exit side of the base film 101, and the light exit side lens portion 103 is formed.

At this time, the film screen 100
Is designed such that the light entrance side lens unit 102 and the light exit side lens unit 103 formed on both sides of the base film 101 are optically positioned and molded.

[0007]

However, in the above-mentioned prior art, it is conceivable that the light-entering lens unit 102 and the light-emitting lens unit 103 are displaced due to the following reasons. The first cause is a displacement due to the thermal behavior (shrinkage) of the base film 101. The base film 101 on the first mold roll 1 is heated by the first ultraviolet lamp 5 (point A), and the base film 101 is formed in an expanded state. It contracts when cooled by the supplied ultraviolet curable resin 103A. Thereafter, the substrate is heated by the second ultraviolet lamp 6 (point B), but it is difficult to make the temperature of the base film 101 at this time equal to the temperature of the base film 101 at point A. In this way, when the mold roll is transferred, the lens molding point is different,
Since it is affected by the thermal behavior of the base film 101, it causes a positional shift.

The thermal behavior of the base film 101 is as follows:
It is also affected by the temperature unevenness (variation) of each mold roll 1 and 2 itself. However, since it is difficult to make the temperatures of the first and second mold rolls 1 and 2 uniform, it is considered that a positional shift occurs. Current mold rolls are temperature-controlled with an accuracy of about ± 1 ° C.

It is known that the thermal behavior of the base film 101 is such that a 1 m film shrinks by 10 to 30 μm due to a temperature change of 1 ° C. It is difficult to adjust the position of the part to the required accuracy of about ± 3 μm.

A second cause is a displacement of a lens position due to a lateral movement of the base film 101 with respect to the first and second mold rolls 1 and 2. The base film 101 has a first
The inclination of the mold roll 1 and the second mold roll 2 (see FIG. 7A), the surface accuracy, the habit of the base film 101, etc.
When the base film 101 moves onto each of the mold rolls 1 and 2, there is a possibility that the base film 101 moves laterally. For this purpose, FIG.
As shown in (B), the center O1 of the light incident side lens portion 102
As a result, a deviation from the center O2 of the light emitting side lens unit 103 occurs.

An object of the present invention is to reduce the influence of the thermal behavior (thermal expansion / shrinkage) of the base film when optical elements such as lenses are formed on both surfaces of the base film using an ionizing radiation curable resin (cancellation). It is an object of the present invention to provide a film screen manufacturing apparatus and a manufacturing method capable of performing alignment with required accuracy easily.

[0012]

According to a first aspect of the present invention, a first forming roll for forming a first optical element on a first surface of a base film is provided.
It is arranged with the molding roll and the base film interposed,
And a second forming roll for forming a second optical element on the second surface of the base film, wherein the first and / or second forming roll has one or both ends thereof. An apparatus for manufacturing a film screen, further comprising: means for preventing displacement of the base film to prevent lateral movement and / or thermal behavior.

According to a second aspect of the present invention, in the apparatus for manufacturing a film screen according to the first aspect, the misalignment preventing means is provided on the first or second forming roll, and When the base film is transferred from a forming roll to the second forming roll, the base film is penetrated or deformed to fix the position with the first and second forming rolls. Device.

[0014] The invention of claim 3 is claim 1 or claim 2.
In the film screen manufacturing apparatus described in,
The apparatus for manufacturing a film screen, wherein the displacement prevention means is a protruding member provided on the first or second forming roll and penetrating or deforming the base film.

According to a fourth aspect of the present invention, a first optical element is formed on a first surface of a base film by a first forming roll, and the first optical element is disposed so as to sandwich the first forming roll and the base film. In the method for manufacturing a film screen, wherein the second optical element is formed on the second surface of the base film by the second forming roll, the first and / or
Alternatively, there is provided a method of manufacturing a film screen, wherein a lateral movement and / or a thermal behavior of the base film are prevented at one end or both ends of a second forming roll.

According to a fifth aspect of the present invention, in the method for manufacturing a film screen according to the fourth aspect, the base film is transferred when the base film moves from the first forming roll to the second forming roll. A method of manufacturing a film screen, wherein the film screen is fixed to the first and second forming rolls by being penetrated or deformed.

[0017]

Embodiments of the present invention will be described below in more detail with reference to the drawings and the like. FIG.
1 is a schematic diagram showing an embodiment of a film screen manufacturing apparatus according to the present invention. In the present embodiment, portions that perform the same functions as those of the above-described conventional example are denoted by the same reference numerals at the end, and redundant description will be omitted as appropriate.

In the apparatus for manufacturing a film screen of this embodiment, small-diameter portions 12a are formed at both ends (only one side is shown in FIG. 1B) of the second die roll 12, and the small-diameter portions 12a are formed on the small-diameter portions 12a. A pin ring 12b provided with a number of pins 12b-1 in the radial direction is inserted, and a threaded stop ring 1 is inserted.
2c. Also, the first mold roll 1
Similarly, a small-diameter portion (not shown) has a pin ring 12.
A rubber receiving ring 11b for receiving the pin 12b-1 of b is inserted and fixed by a threaded retaining ring 11c.

The material of the pin 12b-1 is preferably steel, stainless steel or the like. Also, the pin 12b-
As shown in FIG. 3 (A), the shape of the first mold roll 11 is a conical shape having a sharp tip like a needle and penetrates the base film 101, as shown in FIG.
The base film 101 may be deformed so as to be pressed against it, for example, as shown in FIGS. 3B and 3C, a corner shape or a triangular prism shape. Here, pin 12
Assuming that the height of b-1 is h and the thickness of the base film 101 is t, it is preferable that t <h <2t.

Next, the operation of the manufacturing apparatus according to this embodiment will be described together with its manufacturing method. The ultraviolet curable resin 102A is
It is applied to the first mold roll 11 by the first coating unit 13,
The lens shape of the first mold 11 is transferred by being in close contact with the base film 101 sandwiched between the nip rolls R11. In this state, ultraviolet rays are emitted from the first ultraviolet lamp 15, so that the ultraviolet curable resin 102 </ b> A is cured, and the light incident side lens portion 102 is formed on one surface of the base film 101.

Then, the base film 101 moves from the first mold roll 11 to the second mold roll 12. At this time, the metal pins 12b-1 of the pin rings 12b provided at both ends of the second mold roll 12 penetrate the base film 101 as shown in FIG. It pierces the rubber receiving ring 11c of the mold roll 11. Therefore, the first mold roll 11, the base film 101, and the second mold roll 12 are integrated and positioned, so that the base film moves laterally with respect to the first and second mold rolls 11, 12 and heat is applied. There is no shrinkage due to behavior.

Next, the ultraviolet curable resin 103A is
The coating is applied to the second mold roll 12 by the coating unit 14,
The lens shape of the second mold roll 12 is transferred by being held between the mold roll 11 and the base film 101. In this state, the second ultraviolet lamp 16 is irradiated, so that the ultraviolet curable resin 103A is cured and the base film 10
The light-emitting side lens portion 103 is formed on the other surface of the light-emitting device 1.

Further, the light absorbing layer (black stripe) BS or the like is gravure printed on the light emitting side lens portion 103 of the base film 101 by the printing section 17.

According to this embodiment, the second die roll 12
The lateral movement of the base film 101 and the thermal behavior of the base film 101 can be regulated by the pins 12b-1 of the ring with pins 12b attached to the base member, so that the positioning with the required precision can be performed.

Here, the base film 101 is made of PE
A film having a thickness of 15 to 300 μm, such as T, acrylic, or polycarbonate, can be used, and may be transparent or translucent (containing a diffusing material). As the first and second ultraviolet curable resins 102A and 103A, urethane-based, acrylic-based, urethane acrylate-based, epoxy-based resins and the like are used.

In the film screen manufactured by this manufacturing method, for example, as shown in FIG. 4, lenticular lenses are formed on both sides of a base film 101 as light entrance side and light exit side lens portions 102, 103, Film screen 100A in which light absorbing layer BS is formed on the non-light-emitting portion (projecting portion) on the light-emitting side, base film 1
A lenticular lens is formed as a light-entering lens portion 102 on the light-entering side of No. 01, and a non-light-emitting portion (projection) on the light-emitting side
Screen 100 on which light absorbing layer BS is formed
B, a lenticular lens is formed as a light incident side lens portion 102 on the light incident side of the base film 101, a total reflection type convex lens is formed as a light exit side lens portion 103 on the light exit side, and a light absorbing layer is formed on a non-light emitting portion. Film screen (high contrast screen) 100C with BS formed
And the like. In addition, Japanese Patent Application Laid-Open No.
No. 2,922, JP-A-8-190149, and a film screen of a linear Fresnel lens having a light-entering micro lenticular lens.

As shown in FIG. 5, as a projection television using the film screen of this embodiment, a Fresnel lens sheet 3 is provided from a light source 40 side.
1, a lenticular lens sheet 32 for horizontal diffusion, a lenticular lens sheet 33 for vertical diffusion, and a flat front panel 34, which are the film screens of the present embodiment, can be used. When the light source 40 is a single tube type such as an LCD or a DMD, the light emitting side lens portion of the film lenticular lens sheet 32 may be omitted.

Various modifications and changes are possible without being limited to the embodiment described above, and these are also within the equivalent scope of the present invention. For example, the pins may be provided simultaneously on the first mold roll side and the second mold roll side. Also,
Even if the pin is provided only at one end of the mold roll, there is an effect of positioning. Although an ultraviolet curable resin is described as an example, other ionizing radiation curable resins such as an electron beam curable resin may be used.

[0029]

As described above in detail, according to the present invention, when the base film moves from the first forming roll to the second forming roll, each forming roll and the base film are fixed. , Lateral movement and / or thermal behavior can be prevented, and the positional accuracy of the optical elements formed on both sides of the base film can be improved.

[Brief description of the drawings]

FIG. 1 is a diagram showing an embodiment of a film screen manufacturing apparatus according to the present invention.

FIG. 2 is an enlarged view showing first and second rolls of the film screen manufacturing apparatus according to the embodiment.

FIG. 3 is a diagram showing a shape of a pin of a ring with a pin of the film screen manufacturing apparatus according to the embodiment.

FIG. 4 is a diagram illustrating an example of a film screen manufactured by the manufacturing apparatus according to the embodiment.

FIG. 5 is a diagram showing an example of a transmission screen using a film screen manufactured by the manufacturing apparatus according to the embodiment.

FIG. 6 is a view showing an apparatus for manufacturing a film screen according to a conventional example.

FIG. 7 is a diagram illustrating a problem of a film screen according to a conventional example.

[Explanation of symbols]

 1,11 First die roll 2,12 Second die roll 3,13 First coating unit 4,14 Second coating unit 5,15 First ultraviolet lamp 6,16 Second ultraviolet lamp 7,17 Printing unit 101 Base film 102A, 103A UV curable resin 102 Light entrance lens unit 103 Light exit lens unit BS Light absorbing layer (black stripe)

Claims (5)

[Claims] A first forming roll for forming a first optical element on a first surface of the base film; a second forming roll disposed between the first forming roll and the base film; And a second forming roll for forming a second optical element on the surface of the film screen, wherein the first and / or second forming roll is provided at one end or both ends thereof with the side of the base film. An apparatus for manufacturing a film screen, comprising a displacement preventing means for preventing movement and / or thermal behavior. 2. The film screen manufacturing apparatus according to claim 1, wherein the misalignment prevention means is provided on the first or second forming roll, and the second or third forming roll is moved from the first forming roll to the second forming roll. An apparatus for manufacturing a film screen, wherein when the base film is transferred to a forming roll, the base film is penetrated or deformed to fix the position with the first and second forming rolls. 3. The film screen manufacturing apparatus according to claim 1, wherein the misalignment prevention means is provided on the first or second forming roll, and penetrates or deforms the base film. An apparatus for producing a film screen, wherein the apparatus is a projecting member. 4. A first optical element is formed on a first surface of a base film by a first forming roll, and a second forming roll is interposed between the first forming roll and the base film. A method of manufacturing a film screen for forming a second optical element on a second surface of the base film, wherein the first and / or second forming roll is moved laterally at one or both ends thereof. And / or preventing a thermal behavior. 5. The method of manufacturing a film screen according to claim 4, wherein when the base film moves from the first forming roll to the second forming roll, the base film is penetrated or deformed. And fixing the position to the first and second forming rolls.