JP2002107835A - Lenticular lens sheet, rear projection screen and method of manufacturing the same - Google Patents

Abstract

(57) [Problem] To provide a lenticular lens sheet and a rear projection screen for preventing a gap from being formed between a Fresnel lens sheet due to elongation due to water absorption and distorting an image. Such a lenticular lens sheet 1 is used in a rear projection screen and has a plurality of lenticular lenses 11 arranged on an incident surface of a translucent substrate. Lenticular lens sheet 1
The front plate 2 and the front plate 2 are bonded by an adhesive at, for example, a convex non-light-collecting portion on the light-emitting surface side of the light-transmitting substrate. Then, the lenticular lens sheet 1 and the front plate 2 adhered to each other.
Have a warp that is convex toward the incident surface side.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lenticular lens sheet used for a rear projection television or the like, a rear projection screen, and a method of manufacturing the rear projection screen.

[0002]

2. Description of the Related Art A rear projection screen used for a rear projection television or the like generally has a structure in which two lens sheets are superimposed. That is, a Fresnel lens sheet that narrows down image light from a CRT (Cathode Ray Tube) or image light transmitted through a liquid crystal so as to fall within a certain angle range is arranged on the light source side, and the Fresnel lens sheet is arranged on the observer side. A lenticular lens sheet having a function of spreading the image light transmitted through the lens sheet to a proper angle range is provided.

FIG. 1 is a schematic perspective view of a rear projection type screen.
It is shown in FIG. As shown in FIG. 12, the rear projection screen basically includes a lenticular lens sheet 1 and a Fresnel lens sheet 3. In the lenticular lens sheet 1, a lenticular lens 11 is formed on a surface on which image light is incident. Of the lenticular lens sheet 1, out of the surfaces of the lenticular lens sheet 1 from which the image light is emitted, it is general to form the condensing portion 12 for condensing the light from the lenticular lens 11 formed on the incident side surface into a convex lens shape.
The reason why the condensing portion 12 is formed in a convex lens shape is to enhance the diffusion performance of the image light in the horizontal direction. In the lenticular lens sheet 1 used in combination with a three-tube CRT light source, it is necessary to form the condensing portion 12 in a convex lens shape, in particular, in order to correct color shifts of three colors. Lenticular lens 11 formed on the incident side surface
The non-light-collecting portion 13 (the portion other than the light-collecting portion 12) from which the light from the lens does not converge has a convex shape having a top parallel to the lenticular lens sheet 1. Then, an external light absorbing layer 1301 made of black paint or the like is provided on the top of the convex portion by means of roll coating, screen printing, transfer printing, or the like, so that the convex external light absorbing portion 130 is formed. Thereby, of the external light that has entered the lenticular lens sheet 1, the light that is reflected on the exit surface of the lenticular lens sheet 1 and returns to the observer side is reduced, and the image contrast is improved.

In recent years, the lenticular lens sheet 1 made of a synthetic resin material such as acrylic as a base material has fine irregularities on the observer side to improve the roughness and lack of luxury of the image. It is common to attach a front plate such as an acrylic plate to the observer side. This front plate is also called a translucent sheet, a protection plate, and a contrast filter. However, the provision of the front plate causes problems such as a decrease in productivity due to an increase in the number of components and a decrease in contrast due to an increase in the reflection surface for external light. To solve these problems, Japanese Patent Application Laid-Open Nos. 8-22077, 7-307912, 8-439.
No. 45, JP-A-8-43946, JP-A-8-
JP-A-122921 and JP-A-8-137010 propose a method in which a front plate is bonded and integrated at an external light absorbing portion of a lenticular lens sheet.

[0005] However, the lenticular lens sheet proposed in these documents is convex on the observer side, that is, on the exit surface side due to elongation due to water absorption, and is located between the Fresnel lens sheet provided on the entrance side. There is a problem that a gap is formed and an image is distorted. Regarding this problem, see
In JP-A-22077, by making the water absorption elongation of the front plate integrated with the lenticular lens sheet smaller than the water absorption elongation of the lenticular lens sheet, it becomes convex on the Fresnel lens side in a water-absorbed state and can prevent the screen from floating. It has been proposed. However, when a rear projection screen made of these is set in a rear projection television, the front plate is exposed to the outside, and first, water is absorbed from the front plate side. Therefore, since the front plate has a larger water absorption than the lenticular lens sheet, even if the water absorption elongation is smaller than the lenticular lens, the elongation itself may be large. Occurs.

[0006]

As described above, in the prior art, the lenticular lens sheet is convex to the observer side due to elongation due to water absorption, and a gap is formed between the lenticular lens sheet and the Fresnel lens sheet provided on the incident side. And the image is distorted.

Accordingly, an object of the present invention is to provide a lenticular lens sheet, a rear projection screen, and a method of manufacturing a rear projection screen which prevent a gap from being formed between the Fresnel lens sheet due to elongation due to water absorption and preventing image distortion. To provide.

[0008]

The lenticular lens sheet according to the present invention (for example, the lenticular lens sheet 1 in the present embodiment) is used in a rear projection type screen and has a front plate (for example, a front plate in the present embodiment). A lenticular lens sheet adhered to the face plate 2). The lenticular lens sheet has a plurality of lenticular lenses (for example, the lenticular lens 11 in the present embodiment) arranged on the incident surface of the translucent substrate. The lenticular lens sheet and the front plate are bonded with an adhesive on the light-exiting surface side of the light-transmitting substrate, and have a warp such that the light-projecting surface has a convex shape. According to such a configuration, when used together with the Fresnel lens sheet, a gap is formed between the Fresnel lens sheet and the like due to elongation due to water absorption and the like, and distortion of an image can be prevented.

Further, the lenticular lens sheet according to the present invention is used in a rear projection type screen,
A lenticular lens sheet bonded to the front plate, wherein the lenticular lens sheet includes a plurality of lenticular lenses disposed on an incident surface of the translucent substrate, and a lenticular lens on the exit surface of the translucent substrate. A convex lens portion (for example, the lens portion 12 in the present embodiment) disposed at a light condensing position and a convex lens portion disposed at a position different from the light converging position on the light emitting surface of the translucent substrate. (For example, the non-light-collecting portion 13 in the present embodiment), the lenticular lens sheet and the front plate are bonded with an adhesive at the top of the convex non-light-collecting portion, and It has a warp such that it becomes convex on the incident surface side. With such a configuration,
When used together with a Fresnel lens sheet, a gap is formed between the Fresnel lens sheet and the like due to elongation due to water absorption and the like, and distortion of an image can be prevented.

The rear projection type screen according to the present invention includes a lenticular lens sheet, a front plate, and a Fresnel lens sheet (for example, the Fresnel lens sheet 3 in the present embodiment). The lenticular lens sheet and the front plate have a plurality of lenticular lenses disposed on the incident surface of the substrate, and the lenticular lens sheet and the front plate are bonded by an adhesive on the light-exiting surface side of the light-transmitting substrate, and have a convex shape on the incident surface side. It has a great warpage. With such a configuration, a gap is formed between the lenticular lens sheet and the Fresnel lens sheet due to elongation due to water absorption and the like, and it is possible to prevent the image from being distorted.

A rear projection screen according to the present invention is a rear projection screen provided with a lenticular lens sheet, a front plate, and a Fresnel lens sheet.
The lenticular lens sheet includes a plurality of lenticular lenses disposed on an incident surface of the light-transmitting substrate, and a convex lens portion disposed on a light-condensing position of light from the lenticular lens on an output surface of the light-transmitting substrate. And a convex non-light-condensing portion disposed at a position different from the light-condensing position on the light-emitting surface of the light-transmitting substrate. The lenticular lens sheet and the front plate have a convex non-light-condensing portion. Are bonded by an adhesive at the top, and have a convex warp on the incident surface side. With such a configuration, a gap is formed between the lenticular lens sheet and the Fresnel lens sheet due to elongation due to water absorption and the like, and it is possible to prevent the image from being distorted.

In the rear projection screen described above, it is desirable that the lenticular lens sheet and the front plate adhered to each other have higher rigidity than the Fresnel lens sheet. As a result, the lenticular lens sheet and the front plate restrict warpage, and it is not necessary to warp the Fresnel lens sheet.

On the other hand, a method of manufacturing a rear projection screen according to the present invention is directed to a rear projection screen having a lenticular lens sheet having a plurality of lenticular lenses disposed on an incident surface of a translucent substrate and a front plate and a Fresnel lens sheet. A method of manufacturing a screen, comprising: bonding an lenticular lens sheet and a front plate with an adhesive on an emission surface side of a light-transmitting substrate; and making the entrance surface side convex with respect to the lenticular lens sheet and the front plate. The method includes a step of performing warping, and a step of combining the lenticular lens sheet, the front plate, and the Fresnel lens sheet bonded to each other. With such a configuration, a gap is formed between the lenticular lens sheet and the Fresnel lens sheet due to elongation due to water absorption and the like, and a rear projection screen that can prevent distortion of an image can be manufactured.

Further, according to the method of manufacturing a rear projection screen according to the present invention, there are provided a plurality of lenticular lenses arranged on an incident surface of a translucent substrate, and a light emitted from the lenticular lens on an exit surface of the translucent substrate. A lenticular lens sheet having a convex lens portion disposed at the light-condensing position and a convex non-light-condensing portion disposed at a position different from the light-condensing position on the emission surface of the light-transmitting substrate; A method of manufacturing a rear projection type screen having a front plate and a Fresnel lens sheet, comprising: bonding a lenticular lens sheet and a front plate with an adhesive at a top of a convex non-light-collecting portion; A step of warping the incident surface side with respect to the face plate so as to be convex, a lenticular lens sheet and a front plate adhered to each other, And a step of combining the record panel lens sheet. With such a configuration, a gap is formed between the lenticular lens sheet and the Fresnel lens sheet due to elongation due to water absorption and the like, and a rear projection screen that can prevent distortion of an image can be manufactured.

In the above-described method of manufacturing a rear projection screen, the front plate is heated (for example, heated by the heating means 409) before the step of bonding the lenticular lens sheet and the front plate to thereby warp. The steps to be performed may be executed. With such a configuration, warping can be performed without preparing a warp mold or the like.

Further, before the step of bonding the lenticular lens sheet to the front plate, the step of performing warping by cooling the lenticular lens sheet (for example, cooling by the cooling means 410) may be executed. Good. Even with such a configuration, warping can be performed without preparing a warp mold or the like.

Further, the lenticular lens sheet and the front plate are adhered with an adhesive on a drum (for example, drum 501) having a curve corresponding to a predetermined amount of warping, so that a bonding step between the lenticular lens sheet and the front plate is performed. Then, a warping step may be executed.

[0018]

FIG. 1 is a sectional view of a rear projection screen according to the present invention. In this figure, only the lenticular lens sheet 1 and the front plate 2 are shown, but a Fresnel lens sheet 3 is further provided as in the rear projection type screen shown in FIG.

In the lenticular lens sheet 1, a lenticular lens 11 is formed on a surface on which image light is incident. Further, among the surfaces of the lenticular lens sheet 1 from which the image light is emitted, a light condensing portion 12 for condensing light from the lenticular lens 11 formed on the incident side surface is formed. The non-light-condensing portion 13 formed on the incident surface and on which light from the lenticular lens 11 is not condensed has a convex shape having a top parallel to the lenticular lens sheet 1. The external light absorbing layer 130 is formed on the top of the convex portion.
1 is provided to form a convex external light absorbing portion 130.

The lenticular lens sheet 1 is
For example, it is made of an acrylic resin, a polycarbonate resin, an MS resin (methyl methacrylate, styrene copolymer resin), polystyrene, PET (polyethylene terephthalate), or the like, and may further contain a diffusing material and a tinting agent.

Lenticular lens sheet 1 and front plate 2
Is bonded to the non-light-collecting portion 13 with an adhesive. This adhesive is, for example, an adhesive of a solvent drying type, a thermosetting type, an ultraviolet curing type, an electron beam curing type, or the like. The adhesive may be a transparent adhesive, but preferably uses a light-absorbing black ink or a black adhesive in order not to deteriorate the contrast. The lenticular lens sheet used for bonding may be one in which the convex portion of the bonding surface is previously coated with a light-absorbing black material, and the front plate 2 may be bonded after applying a transparent adhesive or a black adhesive again. However, when a black adhesive is used, the coating of the convex portions of the lenticular lens sheet 1 can be omitted.

The front plate 2 is made of, for example, acrylic resin, polycarbonate resin, MS resin (methyl methacrylate,
(Styrene copolymer resin), polystyrene, PET, etc., with a hard coat, antistatic,
The antireflection treatment or the like may be performed. Further, the front plate 2 may include a diffusing material, a tint agent, or the like inside or on the surface.

Next, a method of manufacturing a lenticular lens sheet and a rear projection screen according to the present invention will be described with reference to FIG.

First, the lenticular lens sheet 1 placed on the conveying means 403 constituted by conveying rollers, conveying belts and the like is conveyed rightward in the drawing. At this time, the non-light-collecting portion 1 provided on the exit surface side of the lenticular lens sheet 1 is formed by the adhesive application roll 402.
On top of 3, an ultraviolet curable adhesive is applied. This adhesive is supplied from the adhesive supply unit 401.

Next, the front plate 2 held by the front plate holding means 404 is conveyed by conveyance rollers 405 so as to overlap the lenticular lens sheet 1 immediately before the bonding nip roll 406. Then, the overlapping lenticular lens sheet 1 and front plate 2 are transported between the bonding nip rolls 4. The lenticular lens sheet 1 and the front plate 2 conveyed between the bonding nip rolls 4 are further conveyed rightward in the drawing as the bonding nip roll 406 rotates. The bonding nip roll 406 has a fixed upper roll and a lower roll, and applies a constant pressure to the lenticular lens sheet 1 and the front plate 2 sandwiched therebetween. As a result, the lenticular lens 1 and the front plate 2 are bonded to each other with an adhesive.

Lenticular lens sheet 1 and front plate 2
After passing through the bonding nip roll 406, ultraviolet rays are irradiated by an ultraviolet irradiation device 407. The irradiation of the ultraviolet rays cures the adhesive, and the lenticular lens sheet 1 and the front plate 2 are permanently bonded. It should be noted that this permanent bonding does not necessarily mean that there is no possibility that both will be peeled off.

Then, the lenticular lens sheet 1 and the front plate 2 that have been bonded are warped. In the warping work, first, the two sheets 101 bonded together
Are stacked and placed on the warp mold 408. At this time, the front plate 2 is positioned on the upper side in the figure. Then, the lenticular lens sheet 1 and the front plate 2
Is left in an oven near the heat distortion temperature of, for example, 60 to 100 ° C. for 1 hour. Thereby, the warping operation is completed. Note that the number of sheets 101 placed on the warp mold 408 is not limited to a plurality, and may be one.

Next, another manufacturing method different from the above-described manufacturing method will be described with reference to FIG. In this manufacturing method, the heating means 409 constituted by a heating wire or the like provides
The method is characterized in that the front plate 2 is heated, and the front plate 2 is warped by utilizing the heat shrinkage of the front plate 2 after the heating.

First, an adhesive is applied to the exit surface side of the lenticular lens sheet 1 by the adhesive applying roll 402 in the same manner as in the above-described manufacturing method. On the other hand, front plate holding means 4
The front plate 2 held by 04 is conveyed by the conveying rollers 405 to the bonding nip roll 406 side.
It is heated to a predetermined temperature by a heating means 409 provided in the middle of the transfer. And the heated front plate 2
Immediately before the bonding nip roll 406, the sheet is conveyed so as to overlap with the lenticular lens sheet 1. Then, the overlapped lenticular lens sheet 1 and front plate 2 are transported between the bonding nip rolls 406. The lenticular lens sheet 1 and the front plate 2 conveyed between the bonding nip rolls 406 are further conveyed rightward in the drawing as the bonding nip rolls 406 rotate. The bonding nip roll 406 has a fixed upper roll and a lower roll, and applies a constant pressure to the lenticular lens sheet 1 and the front plate 2 sandwiched therebetween. As a result, the lenticular lens 1 and the front plate 2 are bonded to each other with an adhesive.

Lenticular lens sheet 1 and front plate 2
After passing through the bonding nip roll 406, the ultraviolet ray is irradiated by an ultraviolet ray irradiation device 407. The irradiation of the ultraviolet rays cures the adhesive, and the lenticular lens sheet 1 and the front plate 2 are permanently bonded.

The front panel 2 is naturally cooled after bonding. At this time, since the front plate 2 is thermally contracted after bonding, the front plate 2 can be warped so that the front plate 2 side is concave, that is, the incident surface side is convex.

Further, another manufacturing method different from the above-described manufacturing method will be described with reference to FIG. This manufacturing method is characterized in that the lenticular lens sheet 1 is cooled by the cooling means 410 constituted by a cooling element or the like, and the lenticular lens sheet 1 is warped by utilizing the subsequent thermal expansion.

First, an adhesive is applied to the exit surface side of the lenticular lens sheet 1 by the adhesive applying roll 402 in the same manner as in the above-described manufacturing method. On the other hand, front plate holding means 4
The front plate 2 held by 04 is conveyed by conveyance rollers 405 so as to overlap the lenticular lens sheet 1 immediately before the bonding nip roll 406.

The lenticular lens sheet 1 is cooled to a predetermined temperature by cooling means provided immediately before the bonding nip roll 406. Then, the lenticular lens sheet 1 and the front plate 2 are transported between the bonding nip rolls 406. This bonding nip roll 4
The lenticular lens sheet 1 and the front plate 2 conveyed during the period 06 are further conveyed rightward in the drawing as the bonding nip roll 406 rotates. The bonding nip roll 406 has a fixed upper roll and a lower roll, and applies a constant pressure to the lenticular lens sheet 1 and the front plate 2 sandwiched therebetween. As a result, the lenticular lens 1 and the front plate 2 are bonded to each other with an adhesive.

Lenticular lens sheet 1 and front plate 2
After passing through the bonding nip roll 4, ultraviolet rays are irradiated by an ultraviolet irradiation device 407. The irradiation of the ultraviolet rays cures the adhesive, and the lenticular lens sheet 1 and the front plate 2 are permanently bonded.

The lenticular lens sheet 1 cooled to a predetermined temperature returns to room temperature after bonding. At this time, since the lenticular lens sheet 1 is thermally expanded after bonding, it is possible to provide a warp such that it is concave on the front plate 2 side, that is, convex on the incident surface side. Here, the convex shape includes a case where only the short side and only the long side of the screen are both convex. In other words,
This includes a case where the screen looks convex when viewed from the side of the screen, a case where the screen looks convex when viewed from above the screen, and a case where the screen looks convex when viewed from the side of the screen or from above. The same applies to the following examples.

It should be noted that in the example shown in FIG.
4, the lenticular lens sheet 1 is cooled by the cooling means 410 in the example shown in FIG. 4, but the respective means 409 and 410 can be performed simultaneously. That is, in a stage before the front plate 2 and the lenticular lens sheet 1 are bonded, the front plate 2 is heated by the heating unit 409, and the lenticular lens sheet 1 is cooled by the cooling unit 410. .

Further, another manufacturing method different from the above-described example will be described with reference to FIG. In this manufacturing method, bonding and permanent bonding of the lenticular lens sheet 1 and the front plate 2 are performed on a drum corresponding to a predetermined warping amount or on a saddle shape forming a part of the drum.

FIG. 5 shows the lenticular lens sheet 1 and the front plate 2 placed on the drum 501. First, the lenticular lens sheet 1 is placed on the drum 501. Thereafter, an adhesive is applied on the lenticular lens sheet 1 by a predetermined method.
Then, the front plate 2 is positioned on the lenticular lens 1 to which the adhesive has been applied, and then placed. Then, a predetermined pressure is applied to the front plate 2 by a predetermined pressing means, so that the two are permanently bonded. As described above, the bonding and permanent bonding of the lenticular lens sheet 1 and the front plate 2 are performed on a drum corresponding to a predetermined warping amount or on a saddle shape forming a part of the drum, whereby the warping is simultaneously performed.

Here, the rigidity of the rear projection type screen will be described.

When the rear projection type screen is considered as a two-dimensional beam with respect to the vertical section as shown in FIG. 6, the deflection d when the upper and lower central portions are pushed from the front by the force of F is expressed by the following equation (1). It can be represented by an equation.

[0042]

(Equation 1) Here, F is the stress (K
g), H is the height (mm) of the screen, E is the Young's modulus (Kg / mm2) of the material of the screen, and Iz is the moment of inertia.

The moment of inertia Iz can be expressed by the following equation (2).

[0044]

(Equation 2) Here, w is the width (mm) of the screen, and T is the thickness (mm) of the screen.

The thickness and the material (Young's modulus) are different.
The deflection d when the two plates are simply bonded without being bonded is
Next, it can be represented by the equation shown in Expression 3.

[0046]

(Equation 3) Here, E1 and Iz1 indicate the Young's modulus and the plate thickness of the lenticular lens sheet 1. E2 and Iz2 indicate the Young's modulus and the thickness of the front plate 2.

As is clear from the equations shown by the equations (1) and (3), in order to select a material having a small rigidity, ie, a deflection d when a constant stress F is applied, a material having a high Young's modulus E is selected. Is preferred. In addition, it is preferable to increase the moment of inertia Iz, that is, to use a thick member and bond it.

The flexural modulus (Young's modulus, Kg / mm2) of various resin materials is shown in Table 1 below.

[0049]

[Table 1] For example, in the case of bonding a 2 mm thick acrylic front plate 2 to a 1 mm thick acrylic lenticular lens sheet 1 in the case of a 50-inch size rear projection screen, comparing the rigidity before and after bonding, Table 2 below
The result is as shown by.

[0050]

[Table 2] Thus, the lenticular lens sheet 1 and the front plate 2
When the same stress is applied to the lenticular lens sheet 1 and the front plate 2, the bending becomes 撓 of the conventional case where the lenticular lens sheet 1 and the front plate 2 are separated. That is, the strength could be improved three times.

Lenticular lens sheet 1 and front plate 2
The case where the rear projection type sheet is configured by combining the integrated sheet with the Fresnel lens sheet 3 having rigidity lower than the rigidity of the sheet will be described. In this case, since the bonded sheets have higher rigidity, the bonded sheets regulate the Fresnel lens sheet 3. Therefore, performing the warping process on the bonded sheets can provide more effective warping than performing the warping process on the Fresnel lens sheet 3. Therefore, it is not necessary to perform the warping process on the Fresnel lens sheet 3.

In the above-described example, the lenticular lens sheet has a convex non-light-collecting portion, and an example in which the lenticular lens sheet is bonded to the front plate with an adhesive at the top of the non-light-collecting portion has been described. Not limited to

For example, as a method for bonding the front plate 2 and the lenticular lens sheet 1, as shown in FIG. 7, an external light absorbing layer 1301 made of a black ink layer is provided on the top of the non-light-collecting portion 13 of the lenticular lens sheet 1. Provided with a black adhesive 1302. 8, a transparent adhesive 1303 may be used instead of the black adhesive 1302.

Further, the lenticular lens sheet 1 of the LCD type rear projection screen may have a flat surface without providing a lens portion on the exit surface side as shown in FIG. The present invention can be applied to the lenticular lens sheet 1 having such a configuration.

In this case, the space between the lenticular lens sheet 1 and the front plate 2 may be filled with a transparent adhesive 1303 as shown in FIG. Further, as shown in FIG. 11, the black ink layer 1301 applied to the non-light-collecting portion 13 and the front plate 2 are bonded with the transparent adhesive 1303 so as to be arranged at a fixed distance. Is also possible.

In the above-described example, the example in which the external light absorbing portion is provided has been described, but the external light absorbing portion is not essential in the present invention.

As described above, the method of manufacturing a lenticular lens sheet according to the present invention is a method of manufacturing a lenticular lens sheet having a plurality of lenticular lenses disposed on the light-incident surface of a light-transmitting substrate. The method includes a step of bonding the lens sheet and the front plate with an adhesive on the light-exiting surface side of the light-transmitting substrate, and a step of warping the lenticular lens sheet and the front plate so that the light incident surface side is convex. is there. With such a configuration, when used together with the Fresnel lens sheet, it is possible to manufacture a lenticular lens sheet capable of preventing a gap from being formed between the Fresnel lens sheet and stretching of the Fresnel lens sheet due to water absorption or the like, thereby preventing image distortion.

Further, the method of manufacturing a lenticular lens sheet according to the present invention comprises the steps of: providing a plurality of lenticular lenses disposed on an incident surface of a light-transmitting substrate; and collecting light from the lenticular lens on an output surface of the light-transmitting substrate. A method of manufacturing a lenticular lens sheet having a convex lens portion disposed at a light position and a convex non-light-condensing portion disposed at a position different from the light-condensing position on the emission surface of the light-transmitting substrate. Then, the step of bonding the lenticular lens sheet and the front plate with an adhesive at the top of the convex non-light-collecting portion and the step of warping the lenticular lens sheet and the front plate so that the incident surface side is convex. It has steps. With such a configuration, when used together with the Fresnel lens sheet, it is possible to manufacture a lenticular lens sheet capable of preventing a gap from being formed between the Fresnel lens sheet and stretching of the Fresnel lens sheet due to water absorption or the like, thereby preventing image distortion.

In the above-described method for manufacturing a lenticular lens sheet, it is preferable to execute a step of warping after the step of bonding the lenticular lens sheet to the front plate.

Further, in the lenticular lens sheet manufacturing method described above, the lenticular lens sheet and the front plate adhered to each other are subjected to a warping process by being heated in a warp mold (for example, a warp mold 408). You may.

Further, in the above-mentioned method of manufacturing a lenticular lens sheet, the lenticular lens sheet and the front plate may be heated to a temperature close to the thermal deformation temperature.

In the above-described method of manufacturing a lenticular lens sheet, the front plate is heated (for example, heated by the heating means 409) before the step of bonding the lenticular lens sheet and the front plate to perform warping. The steps may be executed. With such a configuration, warping can be performed without preparing a warp mold or the like.

Further, before the step of bonding the lenticular lens sheet to the front plate, the step of performing warping by cooling the lenticular lens sheet (for example, cooling by the cooling means 410) may be executed. Good. Even with such a configuration, warping can be performed without preparing a warp mold or the like.

Further, the lenticular lens sheet and the front plate are adhered with an adhesive on a drum (for example, drum 501) having a curve corresponding to a predetermined amount of warping, so that a bonding step between the lenticular lens sheet and the front plate is performed. Then, a warping step may be executed.

The method of manufacturing a rear projection type screen according to the present invention includes a lenticular lens sheet having a plurality of lenticular lenses arranged on an incident surface of a translucent substrate, and a rear projection type having a front plate and a Fresnel lens sheet. A method of manufacturing a screen, comprising: bonding an lenticular lens sheet and a front plate with an adhesive on an emission surface side of a light-transmitting substrate; and making the incident surface side convex with respect to the lenticular lens sheet and the front plate. And a step of assembling the lenticular lens sheet and the front plate adhered to each other with the Fresnel lens sheet. With such a configuration, a gap is formed between the lenticular lens sheet and the Fresnel lens sheet due to elongation due to water absorption and the like, and a rear projection screen that can prevent distortion of an image can be manufactured.

Further, the method of manufacturing a rear projection screen according to the present invention comprises the steps of: providing a plurality of lenticular lenses disposed on the incident surface of the light-transmitting substrate; A lenticular lens sheet having a convex lens portion disposed at the light-condensing position and a convex non-light-condensing portion disposed at a position different from the light-condensing position on the emission surface of the light-transmitting substrate; A method of manufacturing a rear projection type screen having a front plate and a Fresnel lens sheet, comprising: bonding a lenticular lens sheet and a front plate with an adhesive at a top of a convex non-light-collecting portion; A step of warping the incident surface side with respect to the face plate so as to be convex, a lenticular lens sheet and a front plate adhered to each other, And a step of combining the record panel lens sheet. With such a configuration, a gap is formed between the lenticular lens sheet and the Fresnel lens sheet due to elongation due to water absorption and the like, and a rear projection screen that can prevent distortion of an image can be manufactured.

The lenticular lens sheet and the front plate bonded to each other may have higher rigidity than the Fresnel lens sheet. As a result, the lenticular lens sheet and the front plate restrict warpage, and it is not necessary to warp the Fresnel lens sheet.

[0068]

The present invention will be described below in detail with reference to examples. In this example, an acrylic lenticular lens sheet having a lens pitch of 0.72 mm, a thickness of 1 mm, and a size of 50 inches (height 790 mm) was used. After UV-curable black ink was applied to the convex portions of the lenticular lens sheet, a 2 mm acrylic front plate was pressed from above using a nip roller. Immediately after that, ultraviolet light was applied to bond.

80 ° C. × 1 using a warp mold having a warp amount of 20 mm
Hr was warped to give a warp of 12 mm. Then, a 2 mm thick Fresnel lens sheet made of MS resin having no warp was disposed on the back side, and a lenticular lens sheet having a front plate attached thereto was disposed on the front side, and set in a TV set. The warpage to the back side after setting is 8 mm (d /
L = 1.0 × 10−2), and the Fresnel lens sheet and the lenticular lens sheet on which the front plate was bonded were completely adhered, and the image was clear. An environmental test (a heat cycle test at −20 ° C. to 40 ° C.) and a high-temperature and high-humidity test at 40 ° C. 90% Rh were performed on this TV set, and the Fresnel lens sheet and the bonded lenticular lens sheet were completely adhered. There was no deterioration of the image, and the warpage change was stable within 1 mm.

As described above, d / L is 3.0 × 10−3.
It is desired that the value be less than 4.0 × 10−2. More preferably, 6.0 × 10−3 or more and 2.0 × 10−
Desirably less than 2.

[0071]

According to the present invention, it is possible to provide a lenticular lens sheet, a rear projection type screen, and a method for producing the same, which prevent the image from being distorted by forming a gap between the Fresnel lens sheet and the Fresnel lens sheet due to elongation due to water absorption. .

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a rear projection type screen according to the present invention.

FIG. 2 is a lenticular lens sheet according to the present invention;
It is a figure which shows the manufacturing method of a rear projection type screen.

FIG. 3 is a lenticular lens sheet according to the present invention;
It is a figure which shows the manufacturing method of a rear projection type screen.

FIG. 4 is a lenticular lens sheet according to the present invention;
It is a figure which shows the manufacturing method of a rear projection type screen.

FIG. 5 is a lenticular lens sheet according to the present invention;
It is a figure which shows the manufacturing method of a rear projection type screen.

FIG. 6 is a diagram for explaining the rigidity of the rear projection type screen according to the present invention.

FIG. 7 is a cross-sectional view of a rear projection type screen according to the present invention.

FIG. 8 is a cross-sectional view of the rear projection screen according to the present invention.

FIG. 9 is a cross-sectional view of the rear projection type screen according to the present invention.

FIG. 10 is a sectional view of a rear projection type screen according to the present invention.

FIG. 11 is a cross-sectional view of a rear projection type screen according to the present invention.

FIG. 12 is a perspective view of a rear projection type screen according to the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Lenticular lens sheet 2 Front plate 3 Fresnel lens sheet 11 Lenticular lens 12 Condensing part 13 Non-condensing part

Claims (10)

[Claims] 1. Used in a rear projection screen,
A lenticular lens sheet adhered to a front plate, wherein the lenticular lens sheet has a plurality of lenticular lenses disposed on an incident surface of a light-transmitting substrate, wherein the lenticular lens sheet and the front plate are A lenticular lens sheet that is bonded to an exit surface side of a light-transmitting substrate with an adhesive and has a warp such that the incident surface side is convex. 2. Used in a rear projection screen,
A lenticular lens sheet adhered to a front plate, wherein the lenticular lens sheet includes: a plurality of lenticular lenses disposed on an incident surface of a light-transmitting substrate; and the lenticular lens on an emission surface of the light-transmitting substrate. And a convex non-light-collecting portion disposed at a position different from the light-collecting position on the light-emitting surface of the translucent substrate. The lenticular lens sheet and the front plate are bonded to each other with an adhesive at an apex of the convex non-light-collecting portion, and have a warp such that the convex shape is formed on the incident surface side. 3. A rear projection screen including a lenticular lens sheet, a front plate, and a Fresnel lens sheet, wherein the lenticular lens sheet has a plurality of lenticular lenses disposed on an incident surface of a light-transmitting substrate. A rear projection screen in which the lenticular lens sheet and the front plate are bonded with an adhesive on an exit surface side of the light-transmitting substrate and have a warp so as to be convex on an entrance surface side. 4. A rear projection screen comprising a lenticular lens sheet, a front plate, and a Fresnel lens sheet, comprising: a plurality of lenticular lenses disposed on an incident surface of a translucent substrate; Surface, a convex lens portion disposed at a light condensing position of the light from the lenticular lens, and a convex non-light emitting portion disposed at a position different from the light condensing position on an emission surface of the light transmitting substrate. A convergence portion, and the lenticular lens sheet and the front plate are bonded by an adhesive at a top of the convex non-concentration portion, and have a warp such that the convex surface is on the incident surface side. Rear projection screen. 5. The lenticular lens sheet and the front plate bonded to each other have higher rigidity than the Fresnel lens sheet.
A rear projection screen as described. 6. A method for manufacturing a lenticular lens sheet having a plurality of lenticular lenses disposed on an incident surface of a light transmitting substrate, and a rear projection screen having a front plate and a Fresnel lens sheet, wherein the lenticular lens sheet comprises: Adhering the front plate with an adhesive on the light-exiting surface side of the light-transmitting substrate; and warping the lenticular lens sheet and the front plate so that the light incident surface side is convex. Assembling the lenticular lens sheet, the front plate, and the Fresnel lens sheet adhered to each other. 7. A plurality of lenticular lenses disposed on an incident surface of a translucent substrate, and a convex lens disposed on a light exit position of the lenticular lens on an exit surface of the translucent substrate. Lenticular lens sheet having a portion, and a convex non-light-collecting portion disposed at a position different from the light-collecting position on the emission surface of the light-transmitting substrate, a rear projection type having a front plate and a Fresnel lens sheet A method of manufacturing a screen, comprising: bonding the lenticular lens sheet and the front plate with an adhesive at a top of the convex non-light-collecting portion; and incident on the lenticular lens sheet and the front plate. Warping so that the surface side becomes convex; the lenticular lens sheet and the front plate adhered to each other; Method of manufacturing a rear projection screen and a step of combining the Zushito. 8. The method according to claim 6, wherein the step of performing the warping by heating the front plate is performed before the step of bonding the lenticular lens sheet and the front plate. A method for manufacturing a rear projection screen. 9. The step of performing the warping by cooling the lenticular lens sheet prior to the step of bonding the lenticular lens sheet and the front plate. 9. The method for producing a rear projection screen according to 8. 10. A step of bonding the lenticular lens sheet and the front plate by bonding the lenticular lens sheet and the front plate with an adhesive on a drum having a curve corresponding to a predetermined amount of warping; The method of manufacturing a rear projection screen according to claim 6, wherein the warping step is performed.