JP5686005B2 - Optical sheet, display device - Google Patents

Description

The present invention relates to an optical sheet unit optical shape on at least one surface are arrayed is relates to the display equipment.

In recent years, the demand for display devices capable of observing 3D images has increased, and various display devices capable of displaying 3D images have been developed.
For example, a lenticular lens sheet is arranged on the front surface (observer side) of a display panel in which display pixels are arranged in a matrix so that the observer can observe a three-dimensional image without using stereoscopic glasses or the like. Display devices are known.
In this display device, in order to display a clear three-dimensional image, it is necessary to accurately align the unit lens (unit optical shape) and the arrangement pitch of the display pixels. For this reason, in Patent Document 1, alignment markers are provided on the lenticular lens sheet, and alignment is performed with markers provided on the substrate on the display panel side.

JP 2004-280087 A

However, even when the alignment of the lenticular lens sheet and the display panel is performed accurately, if the pitch accuracy of the unit lens of the lenticular lens sheet is not formed well, the arrangement of the display pixels and the unit lens There is a problem in that a clear three-dimensional image cannot be displayed due to a deviation between the two and the arrangement. Therefore, a lenticular lens sheet with high unit lens pitch accuracy is required, and management of the unit lens pitch accuracy during manufacture is important.
However, in the image display device of Patent Document 1, no disclosure is made regarding the management of the accuracy of the pitch of the unit lenses.

An object of the present invention has a high pitch accuracy of the unit optical shape, easy optical sheet subjected to quality control, it is to provide a display equipment including the same.

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.
The invention of claim 1 has an optical shape part (121A) in which a plurality of convex unit optical shapes (122) are arranged in at least one direction along the sheet surface on one surface, At least one mark is provided in the vicinity of both end portions in the arrangement direction of the unit optical shape, and has a mark portion (M) used for length measurement in the arrangement direction, and the mark portion (M) has the unit optical shape. It is an optical sheet (12) characterized by being provided in convex shape in a part of trough part between.
According to a second aspect of the present invention, there is provided the optical sheet according to the first aspect, wherein the top of the mark portion (M) is lower than the top of the unit optical shape (122). It is.
According to a third aspect of the present invention, in the optical sheet according to the first or second aspect, the unit optical shape (122) is a partial shape of a substantially cylindrical shape or a partial shape of a substantially elliptic cylindrical shape, A plurality of optical sheets (12) arranged in one direction along the surface.
According to a fourth aspect of the present invention, in the optical sheet according to any one of the first to third aspects, the mark portion (M) has a substantially square shape when viewed from the normal direction of the sheet surface. The optical sheet (12) is characterized in that one of the diagonal lines connecting the four corners is substantially parallel to the arrangement direction of the unit optical shapes.

The invention of claim 5 is a display unit (11) having a display panel (112) in which a plurality of display pixels (117) for displaying a plurality of images having parallax are arranged in a matrix, and an image of the display unit The optical sheet (12) according to any one of claims 1 to 4, wherein the unit optical shape (122) is arranged on the light emission side so as to be convex on the emission side or convex on the incident side. The display unit simultaneously displays a plurality of images having parallax on the display panel, and the optical sheet causes the image light of the plurality of images having parallax to be emitted in a predetermined direction, respectively. A display device (10) characterized in that it can display a three-dimensional image.
The display device according to claim 6 is the display device according to claim 5, wherein the mark portion (M) is located in an observation region where an image of the display device can be observed. (10).

According to the present invention, the following effects can be obtained.
(1) The optical sheet of the present invention is provided with at least one mark portion near both ends in the arrangement direction of the unit optical shape of the optical shape portion, and has a mark portion used for length measurement in the arrangement direction. The convex portions are provided in the valleys between the unit optical shapes. Therefore, the length measurement can be performed accurately, the mark portion can be easily detected, and the dimension management in the arrangement direction of the unit optical shapes of the optical sheet can be easily performed. This also makes it possible to easily provide a highly accurate optical sheet.

(2) Since the top part of the mark part is lower than the top part of the unit optical shape, the mark part can be easily detected, the length can be easily measured, and damage to the mark part can be prevented.

(3) The unit optical shape is a partial shape of a substantially cylindrical shape or a partial shape of a substantially elliptical column shape, and a plurality of unit optical shapes are arranged in one direction along the sheet surface, so that the shape can be easily formed.

(4) The mark portion has a substantially square shape when viewed from the normal direction of the sheet surface, and one of the diagonal lines connecting the four corners is substantially parallel to the arrangement direction of the unit optical shapes. Can be easily detected, and the center position thereof can be easily detected, thereby improving the accuracy of dimension measurement.

(5) The optical sheet of the present invention and a display unit are provided, the display unit simultaneously displays a plurality of images having parallax on the display panel, and the optical sheet displays video light of the plurality of images having parallax in a predetermined direction. 3D images can be displayed. In addition, it is possible to easily control the shift amount between the display pixel pitch of the display unit and the pitch of the unit optical shape, and it is possible to display a better three-dimensional image.

(6) Since the mark portion is located outside the observation region where the image of the display device is observable, the presence of the mark is not known to the observer when the 3D image is displayed. Can be displayed.

(7) The method for producing an optical sheet of the present invention includes a shaping step for shaping an optical shape portion, and an evaluation step for evaluating dimensions in the arrangement direction of unit optical shapes shaped in the shaping step. The evaluation process includes a detection process for detecting two mark parts located near both ends of the optical shape part along the arrangement direction of the unit optical shapes, and a dimension between the two mark parts detected in the detection process. The length measurement process, the number acquisition process for acquiring the number of unit optical shapes between the two mark portions, and the dimensions obtained in the length measurement process for the number of unit optical shapes obtained in the number acquisition process Is determined to be within a predetermined numerical range, and if it is within the range, it is determined as a non-defective product, and if it is out of the range, it is determined as a defective product. Therefore, it is possible to provide an optical sheet that has higher dimensional accuracy in the arrangement direction of the unit optical shapes and can easily evaluate the dimensions. Since the dimension is evaluated by measuring the dimension between the mark portions and determining whether it is within a predetermined numerical range, it is not necessary to measure each pitch of the unit optical shape, and the evaluation can be performed easily.

(8) In the manufacturing method of the optical sheet, the shaping process is performed by filling the mold with an ionizing radiation curable resin, pressing the substrate with the base material layer, irradiating the ionizing radiation, and curing the ionizing radiation curable resin. A curing step for transferring the shape of the shape portion to the ionizing radiation curable resin layer, and a peeling step for separating the cured base material layer and the ionizing radiation curable resin layer from the mold after the curing step. And the molding die has a convex portion that forms a trough between the unit optical shapes in the vicinity of both ends of the mold shape in the arrangement direction of the concave mold that forms the unit optical shape. A mold for forming a mark portion is formed by cutting a part in a concave shape. Therefore, the mark portion can be created at the same time as the unit optical shape, and manufacturing is easy. The mark part mold is easy to form.

(9) Since the mold is substantially cylindrical and the mold shape is formed on at least a part of the outer peripheral surface thereof, an optical sheet having a high dimensional accuracy of the unit optical shape and which can be easily evaluated and managed. It is cheap and can be manufactured in large quantities.

It is a figure which shows the display apparatus of embodiment. It is a figure explaining the display of a three-dimensional image | video. It is a figure explaining a mark part. It is a figure explaining a part of manufacturing method of a lenticular lens sheet part. It is a figure explaining the shaping | molding die used for formation of a lens layer. It is a figure explaining the dimension evaluation method of a unit lens. It is a figure which shows an example of the deformation | transformation form of a 2nd roll.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In addition, each figure shown below including FIG. 1 is the figure shown typically, and the magnitude | size and shape of each part are exaggerated suitably for easy understanding.
In addition, the terms “plate”, “sheet”, “film” and the like are used, but these are generally used in the order of thickness, “plate”, “sheet”, “film”. I am using it. However, since there is no technical meaning in such proper use, the description in the claims is used in the unified description of the sheet. The terms “sheet”, “plate”, and “film” can be appropriately replaced. For example, the optical sheet may be an optical film or an optical plate.
Furthermore, numerical values such as dimensions and material names of each member described in the present specification are examples of the embodiment, and the present invention is not limited thereto, and may be appropriately selected and used.

(Embodiment)
FIG. 1 is a diagram illustrating a display device of the present embodiment. FIG. 1A shows the layer structure of the display device 10, and FIG. 1B shows the usage state of the display device 10.
The display device 10 of this embodiment includes a display unit 11 and a lenticular lens sheet unit 12. The display device 10 displays an image having parallax on the same frame, and the lenticular lens sheet unit 12 emits light of the image having parallax in a predetermined direction. O is a display device that enables a three-dimensional image to be observed with the naked eye. In FIG. 1, the display unit 11 and the lenticular lens sheet unit 12 are shown to be arranged with a predetermined space therebetween. However, the display unit 11 and the lenticular lens sheet unit 12 are not limited thereto. It is good also as a form laminated | stacked without leaving space between. Further, the lenticular lens sheet portion 12 and the display portion 11 are integrated by being positioned by positioning the peripheral portion thereof by a frame member (not shown).
As shown in FIG. 1B, the display device 10 is not covered with a frame member (not shown) in the use state, and an observation screen that is an area that can be observed by the observer O has a substantially rectangular shape.
In the following description, unless otherwise specified, it is assumed that the screen vertical direction (screen vertical direction) and the screen horizontal direction (screen horizontal direction) are the screen vertical direction and screen horizontal direction in the usage state.

When the display device 10 displays a three-dimensional image, the display unit 11 is a portion that can emit two or more image lights having parallax and display each parallax image simultaneously. The display unit 11 of the present embodiment uses a liquid crystal transmission display device. The display unit 11 includes a surface light source unit 111 and an LCD panel 112.
The surface light source unit 111 is a part that emits light that illuminates the LCD panel 112 from the back side (the side opposite to the observer O side). As the surface light source unit 111, a general-purpose direct type or edge light type surface light source device (backlight) can be used. The light source of the surface light source unit 111 may be, for example, a cold cathode tube, a plurality of LED light sources arranged, an organic EL, or the like, or may be appropriately selected. .

The LCD panel 112 is a transmissive display panel that displays an image, and its observation screen (display surface) has a substantially rectangular shape. In the LCD panel 112, a liquid crystal layer 115 is sealed between two glass substrates 113 and 114.
The LCD panel 112 has three sub-pixels 117 (see FIG. 2) for displaying red (R), green (G), and blue (B) colors arranged in a matrix along a plane parallel to the observation plane. Has been. In the present embodiment, the LCD panel 112 has subpixels 117 arranged in the vertical direction of the screen and the horizontal direction of the screen. In the horizontal direction of the screen, the subpixels 117 of each color are arranged in the order of R, G, and B. Sub-pixels 117 of the same color are arranged in the vertical direction of the screen. In the present embodiment, one pixel 116 includes three sub-pixels 117 that display R, G, and B colors arranged in the horizontal direction of the screen.
The sub-pixel 117 displays a predetermined parallax image when displaying a three-dimensional image, whereby the LCD panel 112 can simultaneously display a plurality of parallax images when displaying a three-dimensional image. The LCD panel 112 of the present embodiment can simultaneously display eight parallax images when displaying a three-dimensional image.
Further, the LCD panel 112 displays one image on all the pixels 116 (sub-pixels 117) when displaying a two-dimensional image.

As shown in FIG. 1, the lenticular lens sheet unit 12 is disposed on the image light emission side (observer O side) of the display unit 11. The lenticular lens sheet unit 12 has a function of emitting a plurality of image lights having parallax emitted from the display unit 11 in predetermined directions.
The lenticular lens sheet portion 12 of the present embodiment includes a lens layer 121, a lens base layer 123, a bonding layer 124, a glass substrate layer 125, and the like in order from the observer O side.
The lens layer 121 has a plurality of unit lenses 122 arranged on the emission side (observer O side) and a mark portion M (see FIG. 1B and FIG. 3 described later) formed between the unit lenses 122. ) Having an optical shape portion 121A. The lens layer 121 is formed of an ultraviolet curable resin on the exit side surface of the lens base layer 123. The lens layer 121 is not limited to the ultraviolet curable resin, and other ionizing radiation curable resins such as an electron beam curable resin may be used.

The unit lens 122 has a substantially cylindrical partial shape, and is a so-called cylindrical lens. A plurality of unit lenses 122 are arranged along the horizontal direction of the screen, with the longitudinal direction being parallel to the vertical direction of the screen.
As shown in FIG. 3A to be described later, the mark portion M is located near both ends in the arrangement direction of the unit lenses 122 of the optical shape portion 121A, and is formed at a position that becomes a valley between the unit lenses 122. Yes. Details of the mark portion M will be described later.
The unit lens 122 has a function of emitting light of a plurality of parallax images displayed on the display unit 11 in a predetermined direction depending on the shape thereof.

  The lens base layer 123 is provided on the display unit 11 side of the lens layer 121 (on the side opposite to the optical shape portion 121A), and serves as a base for forming the lens layer 121, and is formed integrally with the lens layer 121. ing. As the lens base layer 123, a sheet-like member having light permeability can be used.

The bonding layer 124 is a layer that is disposed on the display unit 11 side of the lens base layer 123 and has a function of bonding the lens base layer 123 and the glass substrate layer 125. For the bonding layer 124, for example, a pressure sensitive adhesive, an ultraviolet curable adhesive, or an adhesive can be used.
The glass substrate layer 125 is a light-transmitting glass flat plate, and is provided on the incident side (the display unit 11 side) of the lens base layer 123 via the bonding layer 124. The glass substrate layer 125 has a function of maintaining the flatness of the lenticular lens sheet portion 12 due to its rigidity. Further, the glass substrate layer 125 has a function of adjusting the pixel 116 (liquid crystal layer 115) of the LCD panel 112 at a position substantially equal to the focal point of the unit lens 122 depending on the thickness thereof.

  When the LCD panel 112 displays a large number of parallax images such as four parallax images and six parallax images, for example, the glass substrate layer 125 and the bonding layer as described above are provided in order to secure a focal length. 124 is preferable, but when the LCD panel 112 displays two parallax images (one left-eye image and one right-eye image) or the like, when there is no need to ensure the focal length, the lens The layer 121 and the lens base layer 123 may be used, and the glass substrate layer 125 may not be provided.

FIG. 2 is a diagram for explaining display of a three-dimensional video. In FIG. 2, for easy understanding, the configuration of the lenticular lens sheet unit 12 is simplified and shown as a single layer, and the LCD panel 112 has two parallax images (one left-eye image, An example of displaying one right eye image) will be described.
As shown in FIG. 2, it is assumed that the LCD panel 112 simultaneously displays two parallax images, a right-eye image and a left-eye image, when the 3D image is displayed, and constitutes a pixel 116 of the LCD panel 112. The sub-pixel 117 is configured such that the sub-pixel 117L that displays the left-eye video and the sub-pixel 117R that displays the right-eye video are alternately arranged.

At this time, as shown in FIG. 2, the sub-pixel 117 </ b> L (B) and the sub-pixel 117 </ b> R (G) of the pixel 116-1 correspond to the unit lens 122-1 in the arrangement direction of the unit lenses 122 (the horizontal direction of the screen). , The sub-pixel 117L (R) of the pixel 116-1 and the sub-pixel 117R (B) of the pixel 116-2 correspond to the unit lens 122-2, and the sub-pixel 117L (G) and the sub-pixel 117R ( R) is arranged so as to correspond to each of the unit lenses 122-3. In the case of the configuration shown in FIG. 2, for example, 117R (G) of the pixel 116-1, 117R (B) of 116-2, and 117R (R) of 116-2 display an image as one pixel. .
The unit lens 122 emits the light of the parallax image of each sub-pixel 117 in a predetermined direction. The direction in which the light of the parallax image from each sub-pixel 117 is emitted can be appropriately designed according to optical conditions, use environment conditions, and the like.

As described above, the number of subpixels 117 corresponding to one unit lens 122 corresponds to the number of parallax images displayed on the LCD panel 112. Therefore, when the LCD panel 112 displays eight parallax images as in the present embodiment, there are eight subpixels 117 corresponding to the unit lens 122, and the eight subpixels 117 have their respective parallaxes. Supports video. For example, when the LCD panel 112 displays four parallax images, the number of subpixels 117 corresponding to the unit lens 122 is four, and the four subpixels 117 correspond to the respective parallax images. . The shape of the unit lens 122 is designed so that the light of each parallax image is emitted in a predetermined direction.
In addition, although the unit lens 122 of this embodiment showed the example arranged in the screen left-right direction, it is not restricted to this, For example, angle (alpha) (however, 0 degree <α <90 degrees with respect to the screen left-right direction) ) May be arranged in a direction.

Since the LCD panel 112 and the lenticular lens sheet unit 12 are provided as described above, the display device 10 simultaneously displays the parallax images by the sub-pixels 117 when displaying the three-dimensional image, and the lenticular lens sheet unit 12. The light of each parallax image emitted in a predetermined direction by each unit lens 122 can be observed by the observer O with a corresponding eye at a predetermined position, and a stereoscopic image can be observed.
In addition, the LCD panel 112 displays the same image for all the sub-pixels 117 when displaying a two-dimensional image. Thereby, the display apparatus 10 can provide the observer O with a two-dimensional image.

FIG. 3 is a diagram illustrating the mark portion. FIG. 3A is a perspective view of the lenticular lens sheet portion 12, and FIG. 3B is an enlarged view of the mark portion M from the normal direction of the sheet surface, and FIG. These are the figures which expanded a part of cross section in the arrow AA cross section shown in FIG.3 (b), FIG.3 (d) is the cross section in the arrow BB shown in FIG.3 (b). It is the figure which expanded a part of cross section. 3C and 3D, the bonding layer 124 and the glass substrate layer 125 are omitted for easy understanding.
Here, the sheet surface refers to a surface in the lenticular lens sheet portion 12 that is a planar direction of the lenticular lens sheet portion 12 when the lenticular lens sheet portion 12 is viewed as a whole sheet. And the same definition in the claims. The sheet surface of the lenticular lens sheet unit 12 is a surface parallel to the observation surface of the display unit 11.

In the optical shape portion 121A of the lens layer 121, mark portions M are formed in the vicinity of both end portions in the arrangement direction of the unit lenses 122 as shown in FIG. The mark part M is used for length measurement in the dimension management of the pitch of the unit lenses 122 of the lens layer 121.
In FIG. 3, as an example, a total of two mark portions M are provided, one at a position in the vicinity of both end portions in the arrangement direction of the unit lenses 122 of the lenticular lens sheet portion 12 and in the central portion in the longitudinal direction of the unit lenses 122. Although an example is shown, the number and position of the mark portions M can be changed as appropriate. In the present embodiment, the mark portion M is located outside the observation screen that can be viewed by the observer O, and is covered with the above-described frame member (see FIG. 1B).
The shape of the mark part M will be described. The mark part M is formed in the valley part between the unit lenses 122 in the shape of a dot that is convex on the emission side.

  As shown in FIGS. 3B to 3D, the mark portion M of the present embodiment has a convex shape having a ridge line parallel to the arrangement direction of the unit lenses 122, and is viewed from the normal direction of the sheet surface. The shape is a substantially square shape. One of the diagonal lines connecting the four corners of the substantially rectangular shape of the mark part M is substantially parallel to the longitudinal direction of the unit lens 122 (the extending direction of the valleys), and the other is substantially parallel to the arrangement direction of the unit lenses 122. They are parallel and orthogonal to each other. By adopting such a shape, the center of the mark part M can be easily detected, and the dimension between the mark parts M can be accurately measured. Note that the shape of the mark portion M viewed from the normal direction of the sheet surface is not limited to a substantially rectangular shape, and may be freely selected.

Further, as shown in FIG. 3C, the top of the mark portion M of the present embodiment is formed so as to be lower than the vertex of the unit lens 122. You may form so that it may become higher.
When the top of the mark part M is too low, it is difficult to detect the mark part M. The height from the top of the mark portion M and the bottom of the valley of the unit lens 122 is preferably set as appropriate within a range of 3 to 300 μm according to the lens height, pitch, and the like of the unit lens 122.

The mark part M may be provided outside the observation screen of the display device 10 and at a position covered with a frame member (not shown) that holds the peripheral edge of the display device 10 as in the present embodiment. It may be located in the observation screen. When located within the observation screen, it is preferably provided at a position that becomes the peripheral portion of the observation screen.
FIG. 3A shows an example in which a total of two mark portions M are provided near both ends of the optical shape portion 121A of the lenticular lens sheet portion 12. However, the present invention is not limited to this. For example, the optical shape portion 121A is provided. A total of four unit lenses 122 may be provided, one near each end in the arrangement direction of the unit lenses 122 and one near each end in the longitudinal direction.

(Lenticular lens sheet manufacturing method and unit lens evaluation method)
FIG. 4 is a diagram for explaining a part of the manufacturing method of the lenticular lens sheet portion. FIG. 4A shows a part of the molding apparatus 50 that forms the lens layer 121, and FIG. 4B shows the second roll 53 of the molding apparatus 50 viewed from a direction orthogonal to the direction of the central axis 53a. FIG.
FIG. 4 shows a state in which the lens layer 121 is formed on one side of the lens base layer 123. A molding apparatus 50 shown in FIG. 4 includes a nozzle 51, a first roll 52, a second roll 53, a third roll 54, an ultraviolet irradiation unit 55, a cutting unit (not shown), and the like.
The nozzle 51 supplies uncured ultraviolet curable resin R that forms the lens layer 121 from a resin tank (not shown). The nozzle 51 of the present embodiment discharges the ultraviolet curable resin R onto the outer peripheral surface of the second roll 53, but is not limited thereto, and may be discharged onto the lens substrate layer 123.

The 1st roll 52, the 2nd roll 53, and the 3rd roll 54 are substantially cylindrical shapes, and can be rotationally driven by making the central axis into a rotating shaft.
The first roll 52 is a pressing roll that presses the lens substrate layer 123 against the second roll 53.
As shown in FIG. 4B, the second roll 53 is a forming roll (roll-shaped forming die) having a mold shape portion 531 and a mirror surface portion 532 on the outer peripheral surface thereof.
The mold shape part 531 is a part that becomes a mold for shaping the shape of the optical shape part (unit lens 122 and mark part M) of the lens layer 121, and is a concave mold 531 a that shapes the shape of the unit lens 122. Are arranged and formed. As shown in FIG. 4B, the second roll 53 of the present embodiment is arranged such that the concave mold 531 a that shapes the unit lens 122 is parallel to the direction of the central axis 53 a of the second roll 53. Is formed. The second roll 53 is not limited to this, and the arrangement direction of the concave molds that shape the unit lenses 122 is the circumferential direction or the oblique direction (the direction that forms an angle with respect to the circumferential direction) of the second roll 53. It is good also as a form currently formed.

  As shown in FIG. 4B, the mold 531d for shaping the mark part M is located near both ends of the mold-shaped part 531 and the convex part 531b forming the valleys between the unit lenses 122 is a concave mold. It is formed by cutting linearly parallel to the arrangement direction of 531a. A straight line passing through the mold 531d located in the vicinity of both ends of the mold shape portion 531 is parallel to the arrangement direction of the mold 531a. The mold 531d for shaping the mark portion M may be provided at one place or a plurality of places in the circumferential direction of the second roll 53.

The mirror surface portion 532 is formed at both ends of the second roll 53 with the mold shape portion 531 in between in the direction of the central axis 53 a of the second roll 53. The mirror surface portion 532 is formed with a plurality of grooves having the same shape as the mold 531a so that the resin forming the lens layer 121 does not overflow in the direction of the axis 53a of the second roll 53 in the manufacturing process. It may be.
By forming such a groove or the like, stability during molding is ensured. Such a groove also has an action of preventing chipping (blade chipping) that occurs when a cutting tool is directly inserted into the mirror surface portion.

As shown in FIG. 4A, the third roll 54 is a peeling roll that is provided adjacent to the second roll 53 and peels the lens base material layer 123 from the second roll 53.
The ultraviolet irradiation unit 55 is an apparatus that irradiates ultraviolet rays that cure the ultraviolet curable resin. Since the lens layer 121 of the present embodiment is made of an ultraviolet curable resin, an ultraviolet irradiation unit is used. However, various ionizing radiations such as an electron beam and a visible light are used in accordance with the resin forming the lens layer 121. You may use what irradiates a light ray, a X-ray, a gamma ray, and a particle beam.

The lens base material layer 123 that has been previously formed in a belt shape and wound up in a roll shape is unwound from the roll 123R and supplied to the second roll 53 via the transport roller 56 and the like.
The second roll 53 is filled with the ultraviolet curable resin R that forms the lens layer 121 from the nozzle 51 in the mold shape portion 531 and the mirror surface portion 532 of the outer peripheral surface thereof. The lens base layer 123 is pressure-bonded to the second roll 53 filled with the uncured ultraviolet curable resin R by the first roll 52 and wound around the second roll 53. Then, in a state where the lens base layer 123 is pressure-bonded to the mold shape part 531 of the second roll 53 via the ultraviolet curable resin R, the ultraviolet irradiation unit 55 irradiates ultraviolet rays from the lens base layer 123 side. The ultraviolet curable resin R is cured by the irradiated ultraviolet rays, the optical shape portion 121A (unit lens 122 and mark portion M) of the lens layer 121 is shaped, and the lens layer 121 is formed on one side of the lens base layer 123. Are bonded (curing step).

After the ultraviolet curable resin R is cured, the lens substrate layer 123 is peeled from the second roll 53. The third roll 54 is provided so as to come into contact with the lens base layer 123 that is in close contact with the second roll 53, and the lens base layer 123 is rotated together with the UV curable resin R (lens layer 121) cured by the rotation. And peeling from the second roll 53 (peeling step).
The lens base layer 123 in which the lens layer 121 is integrally formed moves from the third roll 54 to a take-off roll or an adjustment roll (not shown), and then has a predetermined dimension in the flow direction by a cutting part (not shown). Then, the sheet is cut into a sheet-like member, and the process proceeds to an evaluation process for evaluating the accuracy of the unit lens 122.
In the present embodiment, an example of proceeding to the evaluation process after being cut by a not-shown cutting unit has been shown. However, the lens base layer 123 having the lens layer 121 formed on one surface is temporarily wound and stored. Then, it may cut | judge by a cutting part and may progress to an evaluation process.

(About molds)
Here, the manufacturing method of the 2nd roll 53 is demonstrated.
FIG. 5 is a diagram illustrating a mold used for forming the lens layer. 5A shows a state where the mold 531a of the unit lens 122 is formed, and FIG. 5B shows a state where the mold 531d of the mark portion M is formed. FIG. 5C is an enlarged view of the vicinity of the mold 531d of the mark part M, and FIG. 5D is a cross-sectional view of the mold 531d of the mark part M in the axial direction of the second roll 53. The shape indicated by the broken line is the shape before the mold 531d is formed. In order to facilitate understanding, xyz coordinates are provided in FIG. The x coordinate is parallel to the radial direction of the second roll 53 and parallel to the up and down direction in the drawing, the lower side in the drawing is the positive direction, and the z coordinate is in the direction of the central axis 53 a of the second roll 53. Parallel, the right side in the drawing is the positive direction, the y coordinate is the direction parallel to the radial direction of the second roll 53 and perpendicular to the drawing, and the back side of the drawing is the positive direction.

  First, after copper plating is applied to the surface of a metal roll base material, cutting is performed by applying a tool b1 for producing a mold of the unit lens 122 to the outer peripheral surface while rotating the central shaft 53a as a rotation axis. By performing processing or the like, as shown in FIG. 5A, a plurality of concave molds 531a for shaping the shape of the unit lens 122 are arranged and formed. At this time, as shown in FIG. 5 (d), the mold 531a formed in the mold-shaped portion 531 is formed at equal intervals with a pitch P (a dimension between points forming a valley bottom of the mold 531a in the direction of the central axis 53a). The However, in order to perform the cutting process as described above, the die positioned at the end of the die shape portion 531 has a lens width (a dimension between the convex portions 531b in the direction of the central axis 53a) and the lens width of the other die 531a. The lens width W2 is larger than W1.

  Next, after forming a concave mold 531a for shaping the unit lens 122, the shape of the mark part M is shaped at a predetermined position of the mirror surface part 532 of the second roll 53 as shown in FIG. A tool b2 for producing the mold 531d to be formed is applied, the rotation of the second roll 53 is stopped, and a predetermined depth Δx is cut in the negative direction of the x axis (the radial direction of the second roll 53). In this embodiment, the depth at this time is assumed to be shallower than the depth of the concave mold 531a of the unit lens 122. After cutting to a predetermined depth, cutting is performed linearly while moving a predetermined dimension parallel to the negative direction of the z-axis (the left side of the drawing along the arrangement direction of the concave mold 531a) while maintaining the depth. As a result, a straight groove 531c is formed in the mirror surface portion 532, and a part of the convex portion 531b forming a valley between the unit lenses 122 is cut into a groove shape parallel to the arrangement direction of the mold 531a. FIGS. 5C and 5D show, as an example, a state in which two convex portions 531b forming a valley between the unit lenses 122 are cut, but the number of the convex portions 531b to be cut is appropriately set. Selectable.

Thereafter, the cutting tool b2 is moved in the positive direction of the x-axis to move away from the second roll 53, moved to the other end of the mold shape portion 531 along the negative direction of the z-axis, and again in the negative direction of the x-axis. The cutting tool b2 is moved to cut a predetermined amount Δx and cut while moving a predetermined dimension in the negative direction of the z-axis, thereby applying a valley between the unit lenses 122 near the other end of the mold shape portion 531. The convex portion 531b and the mirror surface portion 532 to be formed are cut by predetermined dimensions.
As a result, the second roll 53 has the convex portions 531b and the mirror surface portion 532 of the mold shape portion 531 cut into grooves in the direction parallel to the center axis 53a at both ends of the mold shape portion 531 in the direction of the central axis 53a. A marking line is formed, and a part of the convex part 531b of the mold-shaped part 531 that shapes the valley part between the unit lenses 122 is cut to form the mold 531d of the mark part M.
Note that chipping (blade chipping) is likely to occur when a cutting tool is directly inserted into the mirror surface portion. Therefore, when cutting from the mirror surface portion 532 to the mold shape portion 531 side, it is possible to prevent chipping (blade chipping) by starting cutting from a groove having the same shape as the die 531a formed on the mirror surface portion 532 for resin stopper. It is preferable from the viewpoint.

  As shown in FIG. 3 and the like, the mark portion M has a substantially square shape, one of the diagonal lines is parallel to the arrangement direction of the unit lenses, and the other is the longitudinal direction of the unit lenses (the valleys of the unit lenses). If the shape is parallel to the extending direction of the portion, the center of the mark portion M can be easily observed, and the length measurement described later can be easily performed. Therefore, when creating the mold of the mark portion M, it is preferable to use a cutting tool having a relatively sharp corner at its tip.

(Dimensional evaluation of unit lens)
Here, the pitch dimension evaluation of the unit lens 122 manufactured by the above-described manufacturing method will be described.
FIG. 6 is a diagram for explaining a dimension evaluation method of the unit lens 122.
FIG. 6A shows a sheet-like member (hereinafter referred to as a sheet member) in which an ultraviolet curable resin layer is formed on the lens base layer 123 and is primarily cut to a predetermined dimension in the flow direction. It shows a view from the normal direction. At this time, as shown in FIG. 6A, an optically shaped portion 121A is formed in the central portion of the sheet member, and both end portions of the optically shaped portion 121A have a substantially flat shape to which the shape of the mirror surface portion 532 is transferred. ing. FIG. 6B shows the state of the evaluation method.
A sheet member in which an ultraviolet curable resin layer is formed on the lens base layer 123 is placed on a stage (not shown), and a camera such as a CCD (Charge Coupled Device) image sensor, for example, from the normal direction of the sheet surface. The surface is imaged by 60, and the control unit 61 detects one mark portion M1 from the image data (detection step), and calculates position information (for example, xy coordinates) of the center of the mark portion M1. A plurality of cameras 60 may be used.

Next, the camera 60 images the mark portion M2 located on the other side of the optical shape portion 121A in the arrangement direction of the unit lenses 122 by moving from the mark portion M1 in parallel to the arrangement direction of the unit lenses 122, and the like. The control unit 61 detects the mark part M2 from the imaging data (detection step), and calculates the position information of the center.
And the control part 61 calculates the dimension in the arrangement direction of the unit lens 122 of the mark part M1 and the mark part M2 from the calculated position information of the mark parts M1 and M2 (length measurement process).
In the present embodiment, two mark portions M are provided at both end portions of the optical shape portion 121A, and one of the two mark portions M located inside is used as the mark portions M1 and M2 for length measurement. However, which mark part is used can be appropriately set.

Next, the control unit 61 refers to the number of unit lenses 122 between the mark unit M1 and the mark unit M2 that is input in advance from the input unit 63 and stored in a storage unit (not illustrated) (number acquisition step). Referring to the value within the allowable range of the dimension between the mark parts M1 and M2 (design value ± shift tolerance), the calculated dimension between the mark parts M1, M2 is within the allowable range (design value ± shift) It is determined whether it is within the allowable range (size evaluation step).
When the dimension between the mark parts M1 and M2 is within an allowable range with respect to the number of unit lenses 122 between the mark parts M1 and M2, the distance between the mark parts M1 and M2 It means that the pitch of the unit lenses 122 is formed at a substantially desired pitch.
If the calculated dimension between the mark portions M1 and M2 is within the allowable range (design value ± deviation allowable range), the sheet member is determined to be usable, and the process proceeds to the next step. However, if the calculated dimension between the mark portions M1 and M2 is outside the allowable range, it is determined that the sheet member is unusable, and that fact is displayed on the display monitor 62 and the like. It is discarded without proceeding to the process.

The calculated dimension between the mark portions M1 and M2 is within an allowable range (design value ± deviation allowable range), and the sheet member determined to be usable has a predetermined size by a cutting unit (not shown). And the glass substrate layer 125 is bonded to form the lenticular lens sheet portion 12. The display device 10 is assembled by holding the lenticular lens sheet portion 12 and the display portion 11 together.
At this time, the mark portion M may be present outside the observation screen by being covered with a frame member (not shown) that holds the lenticular lens sheet portion 12 and the display portion 11 as in the present embodiment. It may be located in the observation screen. Even when the mark portion M is present in the observation screen, the mark portion M is very small and becomes a peripheral portion of the observation screen, so that it is difficult to be noticed by the observer O and is provided for viewing the three-dimensional image. The impact is very small. Further, the region having the mark portion M may be cut and used as a form in which the mark portion M does not exist on the lenticular lens sheet portion 12.

Like the display device 10 of the present embodiment, the lenticular lens sheet portion 12 is arranged on the observation surface side of the display panel such as the LCD panel 112 to emit video light having a parallax in a predetermined direction to the observer O. In a display device that displays a three-dimensional image, high accuracy is required for the alignment between the pitch of the unit lenses 122 of the lenticular lens sheet portion 12 and the display pixels (subpixels 117 in the present embodiment). Therefore, in addition to the alignment of the LCD panel 112 and the lenticular lens sheet portion 12, high accuracy is also required regarding the pitch of the unit lenses 122.
When the lens layer 121 and the lens base layer 123 are made of resin as in the lenticular lens sheet portion 12 of the present embodiment, the lens layer 121 contracts when the resin is cured and stretches when the lens base layer 123 is manufactured. For example, the pitch of the unit lenses 122 of the completed lenticular lens sheet portion 12 may deviate from a desired pitch allowable range (design value ± deviation allowable range).
When such a lenticular lens sheet portion 12 is used for the display device 10, it is impossible to emit light having a parallax in a desired direction. For this reason, cross-talk such as a right-eye image that should be observed with the right eye of the observer is observed with the left eye, or stray light is greatly generated, resulting in poor 3D images. It becomes clear.

However, by providing very small mark portions M in the valleys between the unit lenses 122 as in the present embodiment, it is possible to strictly manage the dimensions in the arrangement direction of the unit lenses 122 for a predetermined number of lenses.
Further, the mark portion M is very small, and even if the mark portion M exists in the observation screen, the mark portion M is in the vicinity of the peripheral portion of the observation screen, and therefore, the influence on the display of the three-dimensional image is very small. It is difficult for O to notice the presence of the mark portion M, and the visual recognition of the three-dimensional image is hardly affected.
Further, the shape of the mark portion M is such that when the lens layer 121 is shaped by cutting (scratching) the mold shape portion 531 portion of the second roll 53 linearly along the arrangement direction of the unit lenses 122 with a cutting tool. The mold shape can be easily formed and is easy to manufacture.

  In addition, the unit lens 122b (see FIG. 6A) located at the end of the optical shape portion 121A in the arrangement direction of the unit lenses 122 is a broken line in FIG. 5D compared to the other unit lenses 122. In general, the lens width of the concave mold 531a tends to increase. This is because when the mold shape portion 531 is formed by the processing method shown in FIG. 5A, the cutting tool b1 is processed while being shifted in the arrangement direction, so that the top of the convex portion 531b is more than the surface of the mirror surface portion 532. This is because it tends to be lower.

When the length is measured including such a unit lens 122b and dimension evaluation is performed, the unit lens 122b has a lens width larger than that of the other unit lenses 122 (W1 <W2), so that the accuracy may be lowered. However, since the mark portion M of the present embodiment is formed in the valley between the unit lenses 122, the unit lens 122b is out of the measurement range when measuring the dimension between the mark portions M1 and M2, and the measurement dimension is the unit. There is no influence of the lens width of the lens 122b. Therefore, it is possible to improve the accuracy of dimensional management of the unit lens 122.
From the above, according to the present embodiment, it is possible to provide the display device 10 that can easily manage the pitch dimension of the unit lens 122 and display a clearer three-dimensional image.

(Example)
As one example of this embodiment, the effective screen size is 42 inches diagonal (930 × 523 mm), the size of pixels (R, G, B: 1 set) is about 485 μm, and the resolution is 1920 × 1080 pixels (FHD). The lens sheet used for the display device is prepared.
In the lens sheet of this embodiment, the arrangement pitch of the unit lenses 122 is about 1200 μm, the lens height is about 92 μm, the radius of curvature is about 2000 μm, the thickness of the lens layer 121 is about 112 μm, and the thickness of the lens substrate layer 123. Is about 188 μm. The dimension of the mark portions M1 and M2 is about 100 μm in the arrangement direction of the unit lenses 122, and the height of the unit lenses 122 from the valleys is about 20 μm. In the lens sheet of this embodiment, the unit lenses 122 are arranged in a direction in which the longitudinal direction thereof is approximately 18 degrees with respect to the vertical direction of the screen on the sheet surface. It corresponds to eight subpixels 117 in the direction.
In the case of this embodiment, the height from the top of the mark portions M1 and M2 and the bottom of the valley portion of the unit lens 122 is preferably 50 μm or less.

When the lenticular lens sheet portion 12 was measured between the mark portions M1 and M2 by the above-described length measurement method, the dimension between the mark portions M1 and M2 was within the allowable range (design value ± deviation allowable range). Met.
Accordingly, the dimension between the mark portions M1 and M2 is a non-defective product because the numerical value is within the above-described dimension range. Further, when the display screen is cut and used so that the mark portion M exists, even when a three-dimensional image is displayed, the observer O is not aware of the presence of the mark portions M1 and M2 and is good 3 Dimensional images were observed.
It should be noted that the allowable deviation range with respect to the above-described design value can be appropriately set according to the size of the observation screen, the shape of the unit lens 122, the size of the pixel of the LCD panel 112 to be combined, and the like. For example, in the present embodiment, the allowable deviation from the design value can be about ± 100 μm per meter.

(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 this embodiment, although the example which has the mold shape part 531 which shapes the optical shape part 121A formed in the 2nd roll 53 used as a shaping | molding die was shown, it does not restrict to this, For example, Two or more mold shapes may be provided.
FIG. 7 is a view showing a modified form of the second roll. In FIG. 7, the figure which looked at the 2nd roll 73 of the deformation | transformation form from the direction orthogonal to the central axis 73a is shown.
As shown in FIG. 7, the second roll 73 may be provided with a plurality of mold shape portions 731. Between each mold shape part 731 of the second roll 73 is a mirror surface part 732. If it is set as such a form, the lenticular lens sheet | seat part 12 can be manufactured in large quantities in a short time more cheaply. At this time, the pitches, depths, and the like of the unit lenses formed in each mold shape portion 731 are not constant, and may be different for each mold shape portion 731, for example.
Moreover, in this embodiment, although the shaping | molding die showed the example which is roll shape, it is good also as a flat plate type | mold.

(2) In the present embodiment, the mark part M is used for measuring the dimension in the arrangement direction of the unit lenses 122. However, the present invention is not limited to this, and for example, the mark part M is in the longitudinal direction of the unit lens 122. 2 may be formed so as to be positioned at least two points on the sheet member and used for measuring the dimension of the unit lens 122 in the longitudinal direction. By using in this way, the size of the unit lens 122 in the longitudinal direction can be managed, and the lenticular lens sheet portion 12 with higher accuracy can be provided.

(3) In the present embodiment, the lenticular lens sheet portion 12 has shown an example in which the glass substrate layer 125 is bonded to the lens base layer 123 via the bonding layer 124. The glass substrate layer 125 and the bonding layer 124 may not be provided by increasing the thickness of the 123 sufficiently.
Further, for example, when the display device 10 that displays four or more parallax images at the same time is used, a glass substrate layer 125 is provided to increase the focal length, and the display device that simultaneously displays two parallax images. In this case, the glass substrate layer 125 may not be provided.
In the present embodiment, the unit lenses 122 are arranged in the horizontal direction of the screen, and the longitudinal direction of the unit lenses 122 extends in the vertical direction of the screen. However, the present invention is not limited to this. It may be arranged in parallel with the direction that forms the angle α with respect to the horizontal direction of the screen so that the direction extends in a direction that forms an angle α with respect to the vertical direction of the screen (where 0 ° <α <90 °). Good. By arranging in this way, it is possible to reduce a decrease in resolution in the horizontal direction of the screen.

(4) In this embodiment, the LCD panel 112 has shown an example in which eight parallax images are simultaneously displayed on the same frame. However, the present invention is not limited to this. For example, two LCD images may be displayed. Alternatively, a larger number of parallax images may be displayed.
In addition, the emission direction that is the light peak of each parallax image may be appropriately set according to the usage environment, the characteristics of the display unit 11, and the like, and the unit lens 122 can be designed according to the setting.

(5) In the present embodiment, the lenticular lens sheet unit 12 has been described in which the unit lens 122 is formed on the emission side (observer O side). However, the present invention is not limited thereto. It is good also as a form formed so that it may become convex in the incident side in the side (LCD panel 112 side).

(6) In the present embodiment, the display unit 11 is a liquid crystal transmissive display device and includes an LCD panel and a surface light source unit. However, the display unit 11 is not limited to this, and for example, PDP (Plasma Display Panel) or A display device using an organic EL (OLED: Organic light-emitting diode) display may be used as the display unit 11. By using a display unit in which display pixels emit light such as a PDP or an organic EL display, the brightness of an image can be further improved.

(7) In this embodiment, a light control sheet (not shown) that controls the image light emission direction of the display unit 11 may be disposed between the lenticular lens sheet unit 12 and the display unit 11. As the light control sheet, for example, a general-purpose louver sheet in which light absorption portions and light transmission portions are alternately arranged in a direction parallel to the arrangement direction of the unit lenses 122 may be used. The light absorbing portion and the light transmitting portion may be alternately arranged in a direction parallel to the direction, and the light absorbing portion may have a substantially wedge shape in cross section. At this time, the arrangement pitch of the light absorbing portions is preferably equal to or smaller than the arrangement pitch of the unit lenses 122.
Such a light control sheet may be arranged closer to the observer O than the lenticular lens sheet portion 12 (that is, the observer O side most in the three-dimensional image display device), or the LCD panel 112 and the surface light source. You may arrange | position between the parts 111.

(8) In the present embodiment, the lens layer 121 is formed of an ionizing radiation curable resin such as an ultraviolet curable resin on one surface of the lens base layer 123. However, the present invention is not limited to this. The lens layer 121 and the lens base layer 123 may be integrally formed by extrusion using a plastic resin.

(9) In the present embodiment, an example in which three (R, G, B) subpixels are arranged in the horizontal direction of the screen (stripe arrangement) to form one pixel (pixel) 116 is shown. The arrangement direction of the three subpixels may be the vertical direction of the screen, or may be a form in which the three subpixels are arranged in a delta arrangement.
In the present embodiment, the example in which the number of sub-pixels forming one pixel is three (R, G, B) is shown, but the present invention is not limited thereto, and may be four or more, for example.

(10) In the present embodiment, the surface of the lenticular lens sheet portion 12 may be appropriately subjected to a hard coat treatment, an antireflection treatment, or the like. The antireflection treatment can be appropriately selected and used, for example, by a process such as a WET method or a DRY method, or a method for forming a moth-eye type minute shape. By applying antireflection treatment to the surface of the lens sheet, reflection of external light can be prevented, and a brighter and higher contrast image can be displayed. In addition, the hard coat process can reduce the surface of the unit lens 122 from being damaged.

(11) In the present embodiment, the unit lens 122 of the lenticular lens sheet portion 12 is an example of a part of a substantially cylindrical shape. However, the present invention is not limited to this. For example, the long axis of the unit lens 122 is a sheet. It is good also as a partial shape of the substantially elliptic cylinder shape orthogonal to a surface. The unit lens 122 may be, for example, a microlens array (fly eye lens).

(12) In the present embodiment, the lens layer 121 is formed of an ultraviolet curable resin. However, the present invention is not limited to this. For example, the lens layer 121 is formed by extrusion molding or cast molding using a thermoplastic resin. May be.

  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 to the embodiment described above.

DESCRIPTION OF SYMBOLS 10 Display apparatus 11 Display part 111 Surface light source part 112 LCD panel part 12 Lenticular lens sheet part 121 Lens layer 122 Unit lens 123 Lens base material layer 124 Bonding layer 125 Glass substrate layer M Mark part

Claims (6)

Convex unit optical shape on one surface has an optical shape portion arranged in a plurality along at least one direction along the sheet surface,
The optical shape portion is provided with at least one near each end in the arrangement direction of the unit optical shapes, and has a mark portion used for length measurement in the arrangement direction,
The mark portion is provided in a convex shape in a part of the valley between the unit optical shapes;
An optical sheet characterized by The optical sheet according to claim 1,
The top of the mark portion is lower than the top of the unit optical shape;
An optical sheet characterized by In the optical sheet according to claim 1 or 2,
The unit optical shape is a partial shape of a substantially cylindrical shape or a partial shape of a substantially elliptic cylinder, and a plurality of unit optical shapes are arranged in one direction along the sheet surface,
An optical sheet characterized by In the optical sheet according to any one of claims 1 to 3,
The mark portion has a substantially square shape when viewed from the normal direction of the sheet surface, and one of the diagonal lines connecting the four corners is substantially parallel to the arrangement direction of the unit optical shapes;
An optical sheet characterized by A display unit having a display panel in which a plurality of display pixels each displaying a plurality of images having parallax are arranged in a matrix;
The optical sheet according to any one of claims 1 to 4, wherein the unit optical shape is disposed on the output side of the image light of the display unit so as to be convex on the output side or convex on the incident side. When,
With
The display unit simultaneously displays a plurality of images having parallax on the display panel,
The optical sheet can emit video light of a plurality of videos having the parallax in a predetermined direction and display a three-dimensional video;
A display device. The display device according to claim 5,
The mark portion is located outside an observation region where an image of the display device can be observed;
A display device.

Images