JP4189813B2 - Transmission screen - Google Patents

Description

The present invention relates to a transmissive screen used in a rear projection type projector.

2. Description of the Related Art A transmissive screen for a rear projection display device is known in which a large number of microspherical lenses are fixed on a transparent substrate via a resin.
For example, there is one disclosed in Patent Document 1.
Patent Document 1 discloses a transparent base material, and a large number of microspherical transparent beads composed of a single layer fixed to a colored hot melt adhesive layer composed of a transparent layer and a colored layer formed on the incident light side of the transparent base material. The flat lens used in a rear projection projector that can improve the generation of moire interference fringes, have high contrast, have good resolution, and have high quality is disclosed.

JP-A-9-318801 (page 6, FIG. 1)

However, when this flat lens is manufactured, it is difficult to fix the microspherical lens uniformly and densely on the colored hot melt adhesive layer, and the light incident on the portion where the microspherical lens does not exist is colored hot. Since it is absorbed by the melt adhesive layer, the light transmittance is reduced, so that a bright image cannot be obtained.
As shown in FIG. 6, incident light to the transmission screen 9 is emitted from the microspherical lens 13, and the brightness is determined by the protrusion amount L of the microspherical lens 13 from the surface of the colored layer 12. . The protrusion amount L depends on the film thickness, temperature, and indentation pressure of the transparent layer 11 and the colored layer 12 when the microspherical lens 13 is embedded, but the variation can be controlled uniformly over the entire transparent layer 11. was difficult. This variation has caused a problem in that the brightness distribution varies, resulting in uneven brightness of the image.

  Further, the brightness of the transmissive screen 9 is also determined by the aperture area of the microspherical lens 13 when incident light enters the microspherical lens 13. In order to maximize the aperture area, the brightness of the microspherical lens 13 is incident. On the side, half of the microspherical lens 13 protrudes from the surface of the colored layer 12 so as not to be buried in the colored layer 12. Since the microspherical lens 13 has only a hemispheric surface fixed by the transparent layer 11 and the colored layer 12, depending on vibration, temperature, and humidity, the dimensions of the transparent layer 11 and the colored layer 12 change, thereby forming a microscopic shape. The lens 13 may drop off, causing a problem in reliability.

Accordingly, the present invention has been made in view of the above problems, and an object of the present invention is to provide a transmissive screen used in a rear projection projector that can obtain a bright image without luminance variation and improve reliability. It is what.

The present invention includes a laminated on a transparent substrate transparent adhesive layer formed on the coloring layer, and a mask having a plurality of openings is laminated on the colored layer, it has a two hemisphere, of one A hemispherical surface protrudes from the plurality of openings, the other hemispherical surface protrudes from the colored layer to the transparent adhesive layer side, a plurality of elliptical lenses fixed to the mask and the colored layer, and the mask. is formed, have a connecting portion to integrate all of the hemispherical surfaces of said one of said plurality of said plurality of elliptical lens protruding from the opening by connecting the same material as the material of the plurality of elliptical lens Then, there is provided a transmissive screen characterized in that incident light from the one hemisphere is condensed on the transmissive substrate side via the other hemisphere.

According to the present invention, it possesses a transparent substrate formed on the transparent adhesive layer colored layer laminated on a mask having a plurality of openings is laminated on the colored layer, the two half-sphere, One hemispherical surface protrudes from the plurality of openings, the other hemispherical surface protrudes from the colored layer to the transparent adhesive layer side, and a plurality of elliptical lenses fixed to the mask and the colored layer, and the mask formed thereon, and a connecting portion to integrate all of the hemispherical surfaces of said one of said plurality of said plurality of elliptical lens protruding from the opening by connecting the same material as the material of the plurality of elliptical lens And the incident light from the one hemispherical surface is condensed on the transmissive substrate side via the other hemispherical surface, so that the elliptical lens is masked by environmental changes due to vibration, temperature, and humidity. Falling off the opening of It can be prevented.

A transmission screen and a manufacturing method thereof according to an embodiment of the present invention will be described with reference to FIGS. The same components as those in the conventional example are denoted by the same reference numerals, and the description thereof is omitted.
FIG. 1 is a cross-sectional view showing a transmissive screen used in a rear projection type projector according to an embodiment of the present invention.
2A and 2B show a method for manufacturing a transmission screen according to an embodiment of the present invention. FIG. 2A is a cross-sectional view showing an (ultraviolet curable resin forming step), and FIG. 2B is an ultraviolet curable resin separating step. Sectional drawing, (C) is a sectional view showing (unevenness forming step), (D) is a sectional view showing (hemispherical surface forming step), (E) is a sectional view showing (colored layer forming step), (F) is sectional drawing which shows (adhesion process). FIG. 3 is a diagram showing a change in pressure difference on one surface of the mask higher than the other surface in the process of forming the elliptical lens.

As shown in FIG. 1, in a transmission screen 1 according to an embodiment of the present invention, a colored layer 4 and a mask 5 having a plurality of openings 5 a are sequentially formed on a transparent adhesive layer 3 formed on a transparent substrate 2. The elliptical lens 6 which is laminated and has a plurality of two hemispherical surfaces 6a and 6b is inserted and fixed in the opening 5a, and one hemispherical surface 6b of the elliptical lens 6 has a predetermined amount from the surface of the mask 5. The other hemispherical surface 6a protrudes from the colored layer 4 by a predetermined amount so that incident light from one hemispherical surface 6b is condensed on the transparent substrate 2 side.
The elliptical lens 6 is preferably made of a low-viscosity ultraviolet curable resin, and has a shape that increases the refractive index of the transparent substrate 2, the transparent adhesive layer 3, and the colored layer 4 to increase the lens effect. .

Next, the manufacturing method will be described with reference to FIG.
(UV curable resin formation process)
As shown in FIG. 2A, an ultraviolet curable resin 7 is applied on a mask 5 having a plurality of openings 5a having a predetermined pitch. The mask 5 is preferably a metal thin plate or polymer film having a thickness of 5 μm to 50 μm, and the diameter of each opening 5 a is preferably 10 μm to 100 μm. Further, it is desirable that the pitch of the plurality of openings 5a be short as long as deformation of the mask 5 does not become a problem in the process.

(Insertion process)
Next, as shown in FIGS. 2B and 3, in the process of causing the pressure on the one surface A side of the mask 5 to reach a pressure difference P <b> 1 higher than the pressure on the other surface B side, the ultraviolet curable resin 7. Is inserted into the opening 5 a and separated on the mask 5.
Thereafter, the pressure difference P1 is maintained, and as shown in FIG. 2C, the ultraviolet curable resin 7 is further pushed into the opening 5a so that the one surface A side of the mask 5 is a recess and the other surface. The B side is a convex part. Such a shape is that the surface tension and gravity of the ultraviolet curable resin 7 other than the pressure on the one surface A side being a pressure difference higher by P1 than the pressure on the other surface B side (in FIG. 2, This is because gravity acts on the lower side.)

Further, as shown in FIG. 3, the pressure on one surface A side of the mask 5 is set to a pressure difference P2 lower than the pressure difference P1 higher than that on the other surface B side, and this pressure P2 is maintained. By doing so, convex hemispherical surfaces 6 a and 6 b are formed on both sides of the mask 5.
At this time, the protruding amount Ha of the hemispherical surface 6a from the mask 5 on the back surface is larger than the protruding amount Hb of the hemispherical surface 6b from the surface of the mask 5, and the radius of curvature of the hemispherical surface 6a is smaller than that of the hemispherical surface 6b.
Thereafter, as shown in FIG. 2 (D), ultraviolet rays are irradiated from both sides or one side of the mask 5 to cure the hemispherical surfaces 6a and 6b made of the ultraviolet curable resin 7, thereby forming a plurality of elliptical lenses 6. To do.

  The protrusion Ha of the hemispherical surface 6a from the surface of the mask 5 is the pressure difference P1, P2 between the one surface A side and the other surface B side of the mask 5, and the surface tension between the ultraviolet curable resin 7 and the mask 5. And the direction of gravity. The surface tension is determined by the material and viscosity of the ultraviolet curable resin 7, the material and thickness of the mask 5, and the size of the opening 5a. For this reason, if the ultraviolet curable resin 7 and the mask 5 are determined, the protrusion amount Ha can be controlled by the pressure difference P1, P2. Moreover, since the pressure differences P1 and P2 can be easily made constant over the entire surface of the mask 5, the protruding amounts Ha of all the elliptical lenses 6 can be made uniform. Similarly, the protrusion amount Hb can be made uniform.

(Colored layer formation process)
Next, as shown in FIG. 2E, the colored layer 4 is formed so that a part of the hemispherical surface 6 a of the elliptical lens 6 is exposed on the mask 5 exposed from between the plurality of elliptical lenses 6. . Since the protrusion amount Ha is made uniform in the (insertion step), the height from the surface of the colored layer 4 to the top of the hemispherical surface 6a, that is, the protrusion amount Q can be made constant. The colored layer 4 is preferably made black by adding fine carbon to the resin. Further, the thickness of the colored layer 4 is preferably 5 μm to 50 μm.

(Adhesion process)
Next, as shown in FIG. 2 (F), after forming the transparent adhesive layer 3 on the transparent substrate 2, the hemispherical surface 6a side of the elliptical lens 6 is disposed opposite to the transparent adhesive layer 3, and the transparent substrate A colored layer 4 is bonded together with an elliptical lens 6 through a transparent adhesive layer 3 on 2 to produce a transmission screen 1 shown in FIG. As the transparent substrate 2 and the transparent adhesive layer 3, an acrylic resin having a high light transmittance is desirable. The thickness of the transparent adhesive layer 3 is preferably 5 μm to 50 μm.

  As described above, according to the transmissive screen manufacturing method used in the rear projection type projector of the present invention, in the process of setting the pressure difference P1 on the one surface A side to be higher than the pressure on the other surface B. After the ultraviolet curable resin 7 is inserted into the opening 5a of the mask 5 and separated, the ultraviolet curable resin 7 is pushed into the opening 5a while keeping the pressure difference P1 and is lower than the pressure difference P1. After forming the hemispherical surfaces 6a and 6b on both sides of the mask 5 under the pressure difference P2, a plurality of elliptical lenses 6 are formed by irradiating with ultraviolet rays to form the hemisphere from the colored layer 4 side surface. The protrusion amount Q to the top of the surface 6a can be made uniform. As a result, it is possible to obtain the transmissive screen 1 having a bright image without luminance variation. Moreover, since the high density of the elliptical lens 6 can be achieved by forming the openings 5a at a narrow pitch, an image with high resolution can be obtained.

Next, a modification of the embodiment of the present invention will be described with reference to FIGS.
The same components as those of the embodiment of the present invention are denoted by the same reference numerals, and the description thereof is omitted.
FIG. 4 is a cross-sectional view showing a modification of the embodiment of the present invention. 5A and 5B show a method for manufacturing a transmission screen according to a modification of the embodiment of the present invention. FIG. 5A is a cross-sectional view showing a (connected uneven surface forming step), and FIG. (C) is a cross-sectional view showing (colored layer forming step), and (D) is a cross-sectional view showing (bonding step).
As shown in FIG. 4, the transmissive screen 8 in the modification of the embodiment of the present invention has an elliptical lens 6 connected on the mask 5 on the opposite side of the colored layer 4 in the transmissive screen 1 in the embodiment. The connecting part 6c to be formed is formed, and the other parts are the same.

  In other words, the colored layer 4 and the mask 5 having a plurality of openings 5a are sequentially laminated on the transparent adhesive layer 3 formed on the transparent substrate 2, and an ellipse having a plurality of two hemispherical surfaces 6a and 6b. The shape lens 6 is inserted and fixed in the plurality of openings 5a, and a connecting portion 6c for connecting the elliptical lens 6 is formed integrally with the elliptical lens 6 on the mask 5 on the side opposite to the colored layer 4 side. Thus, one hemispherical surface 6b of the elliptical lens 6 protrudes from the surface of the mask 5 by a predetermined amount, and the other hemispherical surface 6a protrudes from the colored layer 4 by a predetermined amount to receive the incident light from one hemispherical surface 6b. The light is condensed on the transparent substrate 2 side.

Next, the manufacturing method will be described with reference to FIG.
(Connected uneven surface forming process)
As shown in FIG. 5 (A), after performing in the same manner as the (ultraviolet curable resin forming step) shown in FIG. 2 (A) in the embodiment of the present invention, the pressure on one surface A side of the mask 5 is In the process of reaching a pressure difference P 1 higher than the pressure on the surface B side, a part of the ultraviolet curable resin 7 is pushed into the opening 5 a of the mask 5 and also remains on the mask 5.

(Connecting hemisphere forming process)
Next, as shown in FIG. 5B and FIG. 3, after forming the two hemispherical surfaces 6a and 6b on both sides of the mask 5 in a state where the pressure difference P2 is lower than the pressure difference P1, ultraviolet rays are formed. To form a connecting portion 6c that connects the plurality of elliptic lenses 6 and one hemispherical surface 6b of the plurality of elliptic lenses 6 together.

(Colored layer forming step) and (Adhesion step)
Next, as shown in FIGS. 5C and 5D, the same (colored layer forming step) and (adhesion step) as in FIGS. 2E and 2F shown in the embodiment of the present invention are performed. A transmissive screen 8 shown in FIG. 4 is produced.
Here, in the (connected hemispherical surface forming step) shown in FIG. 5B, the height Hc of the connecting portion 6c on the mask 5 is ¼ or less of the projection amount Ha of the hemispherical surface 6b from the surface of the mask 5. It is desirable to be.

  As described above, according to the modification of the embodiment of the present invention, since the plurality of elliptical lenses 6 are fixed by the connecting portion 6c, the elliptical lens 6 is formed on the mask 5 due to environmental changes due to vibration, temperature, and humidity. It can prevent falling off from the opening 5a.

  The present invention can be used for a planar lens used for a viewing angle widening plate such as a plasma display device or an electroluminescence display device, a light diffusion plate for diffusing light such as various illumination light sources, and the like.

It is sectional drawing which shows the transmissive screen in embodiment of this invention. The manufacturing method of the transmission type screen in embodiment of this invention is shown, (A) is sectional drawing which shows (ultraviolet curable resin formation process), (B) is sectional drawing which shows (ultraviolet curable resin separation process), ( (C) is a sectional view showing (unevenness forming step), (D) is a sectional view showing (hemispherical surface forming step), (E) is a sectional view showing (colored layer forming step), (F) is , (Adhesion process). It is a figure which shows the change of the pressure difference in which one surface of the mask in the manufacture process of an elliptical lens is higher than the other surface. It is sectional drawing which shows the modification of embodiment of this invention. The manufacturing method of the transmission type screen in the modification of embodiment of this invention is shown, (A) is sectional drawing which shows (connection uneven | corrugated surface formation process), (B) is a cross section which shows (connection hemispherical surface formation process). (C) is sectional drawing which shows (coloring layer formation process), (D) is sectional drawing which shows (adhesion process). It is sectional drawing which shows the conventional transmissive screen.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1, 8 ... Transmission type screen, 2 ... Transparent base material, 3 ... Transparent adhesive layer, 4 ... Colored layer, 5 ... Mask, 5a ... Opening part, 6 ... Elliptical lens, 6a, 6b ... Hemispherical surface, 6c ... Connection Part 7: UV curable resin

Claims (1)

A colored layer laminated on a transparent adhesive layer formed on a transparent substrate;
A mask having a plurality of openings laminated on the colored layer;
Have a two hemisphere, protrudes from one hemisphere is the plurality of openings, a plurality the other hemisphere protrudes the transparent adhesive layer side from the colored layer, which is fixed to the mask and the colored layer An oval lens,
Connecting said formed on a mask, to integrate all of the hemispherical surfaces of said one of said plurality of said plurality of elliptical lens protruding from the opening by connecting the same material as the material of the plurality of elliptical lens And
A transmissive screen characterized in that incident light from the one hemispherical surface is condensed on the transmissive substrate side via the other hemispherical surface.

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