JP2012159647A - Method for manufacturing transmissive curved surface screen and method for manufacturing display device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a transmissive curved surface screen, by which a transmissive curved surface screen can be easily manufactured, the screen having improved designing property as the screen is formed to have a three-dimensional curved surface, and to provide a method for manufacturing a display device having a transmissive curved surface screen with improved designing property by forming the screen into a three-dimensional curved surface.SOLUTION: The method for manufacturing a transmissive curved surface screen aims to manufacture a transmissive curved surface screen including a laminate that can transmit image light entering a light-entering surface to a light-exiting surface and that is curved to form a three-dimensional curved surface. The method includes: a laminate producing step of producing a laminate in a planar state; and a first curved surface forming step of curving the planar laminate produced in the laminate producing step to form a three-dimensional curved surface. The laminate includes a light-diffusing layer that can diffuse image light to exit. The method for manufacturing a display device employs the above method.

Description

  The present invention relates to a method of manufacturing a transmissive curved screen that is formed to form a three-dimensional curved surface and transmits image light projected from one surface side to the other surface side, and a method of manufacturing the transmissive curved screen. The present invention relates to a method for manufacturing the display device used.

  Conventionally, display devices capable of displaying various images have been incorporated into various systems. In recent years, the field of systems to which display devices are applied has further expanded, and display devices have been incorporated into systems related to daily life. For example, display devices have been applied to fields in which designability is very important, such as automobiles and amusement machines. A display device applied to such a field is not only expected to have a function of displaying an image, but is also required to be harmonized with the entire system from the viewpoint of design.

  In Patent Document 1, it has been studied to curve the image display surface of a liquid crystal display device that has become the mainstream of display devices in recent years. However, as described in paragraph 0004 of Patent Document 1, a liquid crystal display panel of a liquid crystal display device is usually configured to include glass, and considerable contrivance is required even if it is slightly curved. . In view of such a situation, the design of display devices that are actually used has been improved exclusively by adding features to the frame or casing that surrounds the video display surface.

JP 2009-63701 A

  However, it is difficult to impart sufficient designability to the display device simply by devising the frame and the housing.

  Therefore, in view of the above problems, the present invention can easily manufacture a transmission type curved screen having improved design by forming a three-dimensional curved surface. It is an object of the present invention to provide a method for manufacturing a display device including a transmissive curved screen with improved design by forming an original curved surface.

  The present invention will be described below. In order to facilitate understanding of the present invention, reference numerals in the accompanying drawings are appended in parentheses, but the present invention is not limited to the illustrated embodiment.

  The invention according to claim 1 is a transmissive curved screen including a laminate (10) which can transmit image light incident from the light incident surface side to the light output surface side and is bent so as to form a three-dimensional curved surface. In the manufacturing method of (100), the laminated body is produced in a flat plate shape (S11), and the flat laminated body produced in the laminated body production step is formed into a three-dimensional curved surface. And a first curved surface forming step (S12) for bending, and the laminate includes a light diffusing layer (21) capable of diffusing video light and emitting light.

  The invention according to claim 2 is the method of manufacturing the transmissive curved screen (100) according to claim 1, wherein the laminate manufacturing step (S11) is arranged in parallel along the sheet surface so as to transmit light. It includes a step of forming an optical functional layer (12) having a transmission part (13) and a light absorption part (14) arranged in parallel so as to be able to absorb light between the light transmission parts.

  The invention according to claim 3 is the first curved surface forming step (S11) of the method of manufacturing the transmissive curved screen (100) according to claim 1 or 2, wherein the laminate (10) is heated and vacuum molded, It is characterized by performing pressure forming or vacuum / pressure forming.

  In the present invention, “vacuum molding” means a method of molding a molding object by reducing the atmosphere between the molding object and the mold and bringing the molding object into close contact with the mold. Further, in the present invention, “pressure forming” means a method of molding a molding object by pressing the molding object against a mold by pressurization using gas pressure and bringing the molding object into close contact with the mold. Further, in the present invention, “vacuum and pressure molding” means that the molding object is molded by pressing the molding object against the mold by pressurization using gas pressure while reducing the atmosphere between the molding object and the mold. Means how to.

  According to a fourth aspect of the present invention, in the method of manufacturing the transmissive curved screen (100) according to any one of the first to third aspects, the first curved surface forming step (S11) is elliptical or circular in plan view. It is a step of bending the laminate (10) so as to form a three-dimensional curved surface using the molding part of the mold (150, 160) provided with the molding part (151, 161) composed of a convex part or a concave part. And

  According to a fifth aspect of the present invention, in the method of manufacturing the transmissive curved surface screen (100) according to the fourth aspect, the mold used in the first curved surface forming step (S11) includes a plurality of molding parts (151, 161). Further, at least one row is provided, and in a plan view, adjacent molding parts in the row are formed so that a part of each other overlaps.

  Invention of Claim 6 is a manufacturing method of the transmissive | pervious curved screen (100) in any one of Claims 1-5, WHEREIN: A laminated body preparation process (S11) is on the most light-incident surface side of a laminated body. It includes a step of forming a Fresnel lens layer (25).

  In the present invention, the “Fresnel lens layer” means a layer that can function as a Fresnel lens.

  The invention according to claim 7 is a Fresnel lens sheet manufacturing step (manufacturing a Fresnel lens sheet having a Fresnel lens layer) in the method for manufacturing the transmissive curved screen (100) according to any one of claims 1 to 5. S21), the second curved surface forming step (S22) and the first curved surface forming step (S12), which are bent to form a three-dimensional curved surface. And laminating a Fresnel lens sheet, which is produced in the second curved surface forming step (S22) and bent so as to form a three-dimensional curved surface, on the light incident surface side of the body. To do.

  The invention according to claim 8 is the second curved surface forming step (S22) of the method of manufacturing the transmissive curved screen (100) according to claim 7, in which the Fresnel lens sheet is heated and vacuum molded, compressed air molded, or It is characterized by performing vacuum / pneumatic molding.

  According to a ninth aspect of the present invention, in the method of manufacturing the transmissive curved screen (100) according to the seventh or eighth aspect, the second curved surface forming step (S22) includes an elliptical or circular convex portion in plan view, or It is a step of bending the Fresnel lens sheet so as to form a three-dimensional curved surface using the molding part of the mold (150, 160) provided with the molding part (151, 161) formed of a concave part.

  According to a tenth aspect of the present invention, in the method of manufacturing the transmissive curved surface screen (100) according to the ninth aspect, the mold used in the second curved surface forming step (S22) includes a plurality of molding parts (151, 161). Further, at least one row is provided, and in a plan view, adjacent molding parts in the row are formed so that a part of each other overlaps.

  According to the eleventh aspect of the present invention, there is provided a transmissive curved screen including a laminate (10) that is capable of transmitting image light incident from the light incident surface side to the light output surface side and is bent so as to form a three-dimensional curved surface. (100), an image light source (3) that emits image light (L, L ′), and a housing (2, 2 ′) that supports the transmissive curved screen and accommodates the image light source A method of manufacturing an apparatus (1, 1 '), a step of producing a transmissive curved screen by the transmissive curved screen manufacturing method according to any one of claims 1 to 10, an image light source, and a transmissive curved surface And a step of incorporating a screen into a housing.

  According to the method for manufacturing a transmissive curved screen of the present invention, it is possible to easily manufacture a transmissive curved screen having improved design by forming a three-dimensional curved surface. In addition, according to the method for manufacturing a display device of the present invention, a display device including a transmissive curved screen with improved design by forming a three-dimensional curved surface can be easily manufactured.

It is the flowchart which showed the process included in the manufacturing method of the transmissive | pervious curved screen of this invention concerning 1st Embodiment. It is the figure which showed typically a part of cross section about an example of the laminated body produced at the laminated body production process. It is the figure which expanded and showed a part of optical function layer shown in FIG. It is sectional drawing which showed typically an example of the process of forming a light transmissive part. It is the perspective view which showed typically an example of the process of forming a light absorption part. It is the figure which showed typically the optical path of the image light which injected into the Fresnel lens layer. It is the top view which showed an example of the Fresnel lens layer typically. It is the top view which showed typically the other example of the Fresnel lens layer. It is the top view which showed typically the other example of the Fresnel lens layer. It is the figure which showed typically a part of cross section about the other example of the laminated body produced at the laminated body preparation process. It is the perspective view which showed typically the external appearance of the laminated body bent so that the three-dimensional curved surface might be made in a 1st curved surface formation process. FIG. 12A is a cross-sectional view schematically showing a part of the process for an example of the first curved surface forming process. FIG. 12B is a cross-sectional view schematically showing the next step of the step shown in FIG. FIG. 12C is a cross-sectional view schematically showing the next step of the step shown in FIG. FIG. 13A is a cross-sectional view schematically showing a part of the process in another example of the first curved surface forming process. FIG. 13B is a cross-sectional view schematically showing the next step of the step shown in FIG. FIG. 13C is a cross-sectional view schematically showing the next step of the step shown in FIG. Fig.14 (a) is a perspective view which shows roughly an example of the type | mold used for a 1st curved surface formation process. FIG. 14B is a diagram schematically showing a cross section of the mold at XIVb-XIVb shown in FIG. FIG. 14C is a diagram schematically showing a cross section of the mold at XIVc-XIVc shown in FIG. FIG. 15A is a perspective view schematically showing another example of a mold used in the first curved surface forming step. FIG. 15B is a diagram schematically showing a cross section of the mold at XVb-XVb shown in FIG. FIG. 15C is a diagram schematically showing a cross section of the mold at XVc-XVc shown in FIG. FIG. 16A is a perspective view schematically showing another example of a mold used in the first curved surface forming step. FIG. 16B is a diagram schematically showing a cross section of the mold at XVIb-XVIb shown in FIG. FIG. 16C is a diagram schematically showing a cross section of the mold at XVIc-XVIc shown in FIG. It is the flowchart which showed the process included in the manufacturing method of the transmission type curved screen of this invention concerning 2nd Embodiment. It is the figure which showed typically the cross section about an example of the display apparatus manufactured by the manufacturing method of the display apparatus of this invention. It is the figure which showed typically the cross section about the other example of the display apparatus manufactured by the manufacturing method of the display apparatus of this invention.

  The above-described operation and gain of the present invention will be clarified from embodiments for carrying out the invention described below. Hereinafter, the present invention will be described based on embodiments shown in the drawings. In the drawings, for convenience of illustration and easy understanding, the scale and vertical / horizontal dimensional ratios are appropriately changed from those of the actual ones and exaggerated. Moreover, in each drawing, the code | symbol may be abbreviate | omitted for legibility.

1. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a transmissive curved screen comprising: a laminated body that is capable of transmitting image light incident from the light incident surface side to the light emitting surface side and is bent so as to form a three-dimensional curved surface. It is a manufacturing method.

1.1. First Embodiment FIG. 1 is a flowchart showing steps included in a method of manufacturing a transmissive curved screen according to the first embodiment of the present invention. In the method of manufacturing the transmission curved screen of the present invention shown in FIG. 1, the laminated body is produced in a flat plate shape, and a laminated body producing step S11 and the flat laminated body produced in the laminated body producing step S11 are divided into three layers. A first curved surface forming step S12 for bending the original curved surface. Hereinafter, the process shown in FIG. 1 will be described.

<Laminated body production process S11>
The laminate manufacturing step S11 (hereinafter may be simply referred to as “step S11”) is a step of manufacturing a laminate including a light diffusion layer capable of diffusing video light and emitting light in a flat plate shape. FIG. 2 is a diagram schematically showing a part of a cross section of an example of the laminated body manufactured in step S11. In FIG. 2, the left side of the drawing is the light exit surface side, and when the transmissive curved screen provided with the laminate 10 is incorporated in the display device, the viewer observes it (hereinafter referred to as “observer side”). .) In FIG. 2, the right side of the drawing is the light incident side, which is the side on which the image light source is provided (hereinafter referred to as “image light source side”).

  2 includes a hard coat layer 20, a light diffusion layer 21, a pressure-sensitive adhesive layer 22a, an optical functional layer 12, a base material layer 11, a pressure-sensitive adhesive layer 22b, a reinforcing layer 23, a pressure-sensitive adhesive layer 22c, and a base. It has a material layer 24 and a Fresnel lens layer 25. The laminate 10 is produced by laminating the sheets constituting these layers and then cutting them to an appropriate size, or by laminating the sheets constituting these layers to an appropriate size and then laminating them. be able to. The lamination method of each layer is not specifically limited, A well-known method can be used.

(Hard coat layer 20)
The hard coat layer 20 is disposed on the most observer side of the laminate 10 and constitutes a video display surface of a transmissive curved screen provided with the laminate 10. Therefore, the hard coat layer 20 is given resistance to scratches caused by contact with the outside. Such a hard coat layer 20 can be formed, for example, by curing an ionizing radiation curable resin. Specific examples of the ionizing radiation curable resin include acrylic urethane ionizing radiation curable resins.

  In addition, the hard coat layer 20 preferably has an antiglare function in order to constitute a video display surface of a transmissive curved screen provided with the laminate 10. According to the hard coat layer 20 having the anti-glare function, reflection of external light on the display surface of the transmissive curved screen and reflection of an external image are prevented, and an image displayed on the display surface of the transmissive curved screen is prevented. Visibility can be improved.

  Such a hard coat layer 20 is formed on the light diffusion layer 21 by, for example, continuously supplying the resin constituting the hard coat layer 20 to one surface side of the light diffusion layer 21 and performing molding. Can be laminated. At this time, when the hard coat layer 20 is provided with the above-described antiglare function, for example, it may be formed by using a mold roll whose surface is a matte surface.

  However, if the laminate 10 including the hard coat layer 20 is bent as described later after the hard coat layer 20 is cured, the hard coat layer 20 may be cracked. This is because when the resin constituting the hard coat layer 20 is completely cured, the hard coat layer 20 becomes difficult to extend and cannot follow bending.

  Therefore, the following method can be illustrated as a preferable method for providing the hard coat layer 20 on one surface side of the light diffusion layer 21. In the first method, the resin constituting the hard coat layer 20 is not completely cured in step S11, and the process proceeds to the next step. At the same time the laminate 10 is bent in the first curved surface forming step S12, or the laminate 10 This is a method of curing the hard coat layer 20 after bending. In the second method, after the laminate 10 is bent, the resin constituting the hard coat layer 21 is applied to the surface of the light diffusion layer 21 by spray coating, spin coating, dip coating, and the like. , A method of curing the resin.

(Light diffusion layer 21)
The light diffusion layer 21 is a layer that isotropically diffuses light incident from the image light source side and emits the light to the viewer side. Specifically, the light diffusion layer 21 has a base portion made of a transparent resin and a diffusion component dispersed in the base portion. The light diffusing layer 21 functions to diffuse light isotropically, for example, due to a difference in refractive index between the base portion and the diffusing component, or due to the reflectivity of the diffusing component itself. Is expressed. However, in the present invention, the light diffusion layer 21 is not limited to a layer that diffuses light isotropically, and may be a layer that anisotropically diffuses light according to the application of the transmissive curved screen. For example, light can be anisotropically diffused by adjusting the distribution of the diffusion component in the base portion and the shape of the diffusion component. Due to the light diffusing ability of the light diffusing layer 21, the image light transmitted through the optical functional layer 12 is diffused, and the observer observes the image within the range of the viewing angle corresponding to the light diffusing ability of the light diffusing layer 21. can do.

  Examples of the transparent resin constituting the base portion of the light diffusion layer 21 include methyl methacrylate / butadiene / styrene copolymer (MBS resin), methyl methacrylate / styrene copolymer (MS resin), acrylic resin, polycarbonate resin, and the like. Can be mentioned.

  Moreover, as what comprises the diffusion component of the light-diffusion layer 21, organic fillers, such as a plastic bead, are suitable, and a thing with especially high transparency is preferable. Examples of the plastic beads include melamine beads, acrylic beads, acrylic-styrene beads, polycarbonate beads, polyethylene beads, polystyrene beads, and vinyl chloride beads. Among these, acrylic beads are preferable. Alternatively, the diffusion component may be a bubble.

  The thickness of the light diffusion layer 21 is preferably 0.1 mm or more and 2 mm or less, and more preferably 0.2 mm or more and 1.5 mm or less. If the thickness of the light diffusion layer 21 is less than 0.1 mm, the light diffusion capability of the light diffusion layer 21 may be insufficient. On the other hand, if the thickness of the light diffusion layer 21 exceeds 2 mm, the resolution of the image displayed on the transmissive curved screen provided with the laminate 10 may deteriorate, and the image may be blurred.

  Such a light diffusing layer 21 is prepared, for example, by adjusting a thermoplastic resin in which the diffusing component is dispersed in the transparent resin, and producing a diffusion film in which the thermoplastic resin is formed into a plate shape by extrusion molding. Can be formed by laminating to the other layer. The method for laminating the light diffusion layer 21 and other layers is not particularly limited. For example, the hard coat layer 20 can be laminated with the light diffusion layer 21 as described above. Moreover, as shown in FIG. 1, the optical function layer 12 and the light-diffusion layer 21 can be laminated | stacked by bonding using the adhesive layer 22a.

(Optical function layer 12)
The optical functional layer 12 is a layer having a function of appropriately absorbing stray light and external light while controlling the optical path of the image light incident from the image light source side. The optical functional layer 12 has a cross section shown in FIG. 2 and a shape extending to the back / near side of the drawing. FIG. 3 is an enlarged view of a part of the optical functional layer 12 shown in FIG. The optical functional layer 12 will be further described with reference to FIGS.

  The optical functional layer 12 includes light transmitting parts 13, 13,... Arranged in parallel along the layer surface so that light can be transmitted, and a light absorbing part 14 arranged in parallel so as to absorb light between the light transmitting parts 13, 13,. , 14,..., And the light transmitting portions 13, 13,... And the light absorbing portions 14, 14,... Have a shape that has the cross section shown in FIG. I have. The optical functional layer 12 includes the light transmitting portions 13, 13,... And the light absorbing portions 14, 14, so that the optical path of the image light incident from the image light source side when provided in the display device. It is possible to have a function of appropriately absorbing stray light and external light.

  The light transmitting portions 13, 13,... Are elements having a function of transmitting image light, and are elements having a substantially trapezoidal cross section in the cross sections shown in FIGS. An upper base and a lower base longer than the upper base in the substantially trapezoidal cross section are arranged in a direction along the layer surface of the optical functional layer 12. Further, the light transmitting portions 13, 13,... Have a refractive index of Np and have light transmittance. Such a light transmission part 13,13, ... can be comprised by hardening the light transmission part structure composition demonstrated below. The value of the refractive index Np is not particularly limited, but is preferably 1.49 to 1.56 from the viewpoint of the availability of the applied material.

  The light transmissive part constituting composition is preferably one that can be cured by light such as ultraviolet rays. For example, the following photocurable prepolymer (P1), reactive diluent monomer (M1), and photopolymerization initiator (S1) A photocurable resin composition containing the above is preferably used.

  Examples of the photocurable prepolymer (P1) include epoxy acrylate-based, urethane acrylate-based, polyether acrylate-based, polyester acrylate-based, and polythiol-based prepolymers.

  Examples of the reactive dilution monomer (M1) include vinyl pyrrolidone, 2-ethylhexyl acrylate, β-hydroxy acrylate, and tetrahydrofurfuryl acrylate.

  Examples of the photopolymerization initiator (S1) include hydroxybenzoyl compounds (2-hydroxy-2-methyl-1-phenylpropan-1-one, 1-hydroxycyclohexyl phenyl ketone, benzoin alkyl ether, etc.), benzoyl Formate compounds (such as methylbenzoylformate), thioxanthone compounds (such as isopropylthioxanthone), benzophenones (such as benzophenone), phosphate compounds (1,3,5-trimethylbenzoyldiphenylphosphine oxide, bis (2,4,6-) Trimethylbenzoyl) -phenylphosphine oxide and the like, and benzyldimethyl ketal and the like. Of these, 2-hydroxy-2-methyl-1-phenylpropan-1-one, 1-hydroxycyclohexyl phenyl ketone, and bis (2,4) are preferable from the viewpoint of preventing coloring of the light transmitting portions 13, 13,. , 6-trimethylbenzoyl) -phenylphosphine oxide. In addition, it is preferable that the said photoinitiator (S1) is contained 0.5 mass% or more and 5.0 mass% or less on the basis (100 mass%) of light transmission part structure composition whole quantity.

  These photocurable prepolymer (P1), reactive diluent monomer (M1) and photopolymerization initiator (S1) can be used alone or in combination of two or more. In addition, in the light transmitting part constituting composition, if necessary, silicone additives, rheology control agents, It is also possible to add a defoaming agent, a release agent, an antistatic agent, an ultraviolet absorber and the like. However, as described below, it is preferable to use an ultraviolet curable resin having a molecular weight between crosslinks of 3000 or more and 4000 or less for the light transmitting part constituting composition.

  The ultraviolet curable resin becomes soft (easily stretched) when the molecular weight between crosslinks is increased, and the shape of the soft ultraviolet curable resin is easily changed when molded. The present inventors conducted an experiment on the assumption that it is preferable to use a moderately soft ultraviolet curable resin in the present embodiment. As a result, an ultraviolet curable resin having a molecular weight between crosslinks of 3000 or more and 4000 or less is used. Has been found to be preferable. Below, an example of the experiment which the inventor performed is demonstrated.

  The inventor prepared a plurality of sheets each having an optical functional layer having a light transmission part formed of different resins, and conducted an experiment in which these sheets were molded to have a three-dimensional curved surface using various molds. went. Table 1 shows the shape of the mold used in the experiment and the resin used. The resin used in this experiment is a resin having a molecular weight between crosslinks of 1500 (resin A) and a resin having a molecular weight between crosslinks of 3250 (resin B). Moreover, the type | mold used for this experiment is a type | mold as shown in FIG. 14 (a) is a perspective view of the mold 140, FIG. 14 (b) is a cross section taken along XIVb-XIVb shown in FIG. 14 (a), and FIG. 14 (c) is shown in FIG. 14 (a). It is the section in XIVc-XIVc. The “curvature radius” shown in Table 1 is the radius of curvature in the longitudinal direction of the concave portion (molded portion) 141 of the mold 140. “Depth” is the depth D 1 of the recess 141. “Longitudinal change rate” is the length L2 of the arc 144 that forms the bottom in the longitudinal section of the recess 141 (the section shown in FIG. 14B), and the length L1 of the recess 141 in the longitudinal direction in plan view. Is a value obtained by (L2−L1) / L1. “Area change rate” is a value obtained by calculating the change rate in the short direction in the same manner as the change rate in the longitudinal direction and multiplying the change rate in the short direction and the change rate in the longitudinal direction. “Vertical stripe” indicates whether or not a crack has occurred when molding is performed such that the longitudinal direction of the light transmission part (the rear side / front side in FIG. 2) is parallel to XIVb-XIVb. “Stripe” indicates whether or not a crack has occurred when molding is performed such that the longitudinal direction of the light transmitting portion (the rear side / front side in FIG. 2) is parallel to XIVc-XIVc. In addition, when a crack generate | occur | produces, it is set as "(circle)" when a crack does not generate | occur | produce.

  As shown in Table 1, when an ultraviolet curable resin having a molecular weight between crosslinks of 3250 was used, no crack was generated even when the area change rate was extended to 19.4%.

  Next, the light absorbers 14, 14,... Will be described. The light absorbing portions 14, 14,... Are elements that are disposed between the light transmitting portions 13, 13,... And have a substantially trapezoidal surface in the cross section shown in FIGS. In the substantially trapezoidal cross section of the light absorbing portions 14, 14,..., An upper base and a lower base longer than the upper base are arranged in a direction along the layer surface of the optical function layer 12. In addition, a surface corresponding to the lower base of the substantially trapezoidal cross section of the light absorbing portions 14, 14,... Is juxtaposed between the upper bases of the light transmitting portions 13, 13,. And one surface of the optical functional layer 12 is formed by the lower base of the light absorption parts 14, 14,... And the upper base of the light transmission parts 13, 13,. It is preferable that the hypotenuse in the substantially trapezoidal cross section of the light absorbing parts 14, 14,... If the angle of the hypotenuse is close to 0 degrees, the cross section of the light absorbing portions 14, 14,... Further, the inclination of the oblique sides of the light absorbing portions 14, 14,... Is not necessarily constant, and may be a polygonal line or a curved line. Furthermore, the light absorbing portions 13, 13,... May have a substantially triangular cross section.

  Further, the light absorbing portions 14, 14,... Are made of a predetermined material having a refractive index Nb smaller than the refractive index Np of the light transmitting portions 13, 13,. In this way, by setting the refractive index Np of the light transmitting portions 13, 13... And the refractive index Nb of the light absorbing portions 14, 14,... To Np> Nb, the image light source incident on the light transmitting portions 13, 13,. Are reflected by Snell's law at the interface between the light absorbing parts 14, 14,... And the light transmitting parts 13, 13,. The difference in refractive index between Np and Nb is not particularly limited, but is preferably greater than 0 and 0.06 or less.

  Further, in the present embodiment, the relationship of Np> Nb is preferable as described above, but is not necessarily limited to this, and the refractive index of the light transmission part and the refractive index of the light absorption part may be the same. It is also possible to make the refractive index of the light transmission part smaller than the refractive index of the light absorption part.

  In addition, the light-absorbing part 14, 14,... In the present embodiment is a light-absorbing part-constituting composition comprising the light-absorbing particles 16, 16,... And the binder 15 in which the light-absorbing particles 16, 16,. It is configured by filling a groove between the light transmitting portions 13, 13,. As a result, the stray light incident on the inside of the light absorbing portions 14, 14,... Without being reflected by Snell's law at the interface between the light transmitting portions 13, 13,... And the light absorbing portions 14, 14,. 16, 16, ... can be absorbed. Furthermore, the external light from the observer side incident at a predetermined angle can be appropriately absorbed by the light absorbing particles 16, 16,..., And the contrast of the image can be improved.

  At this time, the binder 15 is made of the material having the refractive index Nb. Although what is used as the said binder is not specifically limited, What is hardened | cured by light, such as an ultraviolet-ray, is preferable, for example, a reactive dilution monomer (M2) and photopolymerization start to a photocurable prepolymer (P2) A photocurable resin composition containing the agent (S2) is preferably used.

  Examples of the photocurable prepolymer (P2) include urethane (meth) acrylate, polyester (meth) acrylate, epoxy (meth) acrylate, and butadiene (meth) acrylate.

  Examples of the reactive dilution monomer (M2) include monofunctional monomers such as N-vinyl pyrrolidone, N-vinyl caprolactone, vinyl imidazole, vinyl pyridine, styrene, and other vinyl monomers, lauryl (meth) acrylate, stearyl ( (Meth) acrylate, butoxyethyl (meth) acrylate, ethoxydiethylene glycol (meth) acrylate, methoxytriethylene glycol (meth) acrylate, methoxypolyethylene glycol (meth) acrylate, methoxydipropylene glycol (meth) acrylate, paracumylphenoxyethyl (meth) ) Acrylate, nonylphenoxy polyethylene glycol (meth) acrylate, tetrahydrofurfuryl (meth) acrylate, isobornyl (meth) a (Meth) acrylic acid ester monomers such as relate, cyclohexyl (meth) acrylate, benzyl methacrylate, N, N-dimethyl (meth) acrylamide, N, N-dimethylaminopropyl (meth) acrylate, acryloylmorpholine, A (meth) acrylamide derivative is mentioned. Polyfunctional monomers include ethylene glycol di (meth) acrylate, diethylene glycol di (meth) acrylate, triethylene glycol di (meth) acrylate, polyethylene glycol di (meth) acrylate, tripropylene glycol di (meth) acrylate, polytetra Methylene glycol di (meth) acrylate, 1,4-butanediol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, 1,9-nonanediol di (meth) acrylate, 3-methyl-1, 5-pentanediol di (meth) acrylate, neopentyl glycol di (meth) acrylate, dimethylol-tricyclodecane di (meth) acrylate, hydroxypivalate neopentyl glycol di (meth) acrylate Bisphenol A polypropoxydiol di (meth) acrylate, trimethylolpropane tri (meth) acrylate, ethoxylated trimethylolpropane tri (meth) acrylate, propoxylated trimethylolpropane tri (meth) acrylate, pentaerythritol tri (meth) Acrylate, glyceryl tri (meth) acrylate, propoxylated glyceryl tri (meth) acrylate, tris (2-hydroxyethyl) isocyanurate triacrylate, pentaerythritol tetra (meth) acrylate, ditrimethylolpropane tetra (meth) acrylate And dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) acrylate, and the like.

  Examples of the photopolymerization initiator (S2) include 1-hydroxycyclohexyl phenyl ketone, 2-hydroxy-2-methyl-1-phenylpropan-1-one, 2,2-dimethoxy-1,2-diphenylethane- Examples include 1-one, 2,4,6-trimethylbenzoyldiphenylphosphine oxide, and bis (2,4,6-trimethylbenzoyl) -phenylphosphine oxide. Among these, the irradiation device for curing the photocurable resin composition and the curability of the photocurable resin composition can be arbitrarily selected. In the present invention, the amount of the photopolymerization initiator (S2) contained in the photocurable resin composition is based on the total amount of the photocurable resin composition from the viewpoint of curability and cost of the photocurable resin composition (100 mass). %) Is preferably included in an amount of 0.5% by mass or more and 10.0% by mass or less.

  These photocurable prepolymer (P2), reactive diluent monomer (M2) and photopolymerization initiator (S2) can be used alone or in combination of two or more.

  Specifically, refraction of polymerizable components (specifically, photocurable prepolymer (P2) and reactive dilution monomer (M2)) composed of urethane acrylate, epoxy acrylate, tripropylene glycol diacrylate and methoxytriethylene glycol acrylate. The ratio, viscosity, or influence on the performance of the optical function layer 12 is taken into consideration and used.

  Moreover, you may add a silicone, an antifoamer, a leveling agent, a solvent, etc. to a light absorption part structure composition as an additive as needed.

  The light absorbing particles 16, 16,... Are included in the light absorbing portion constituting composition, and act to absorb stray light and external light when the light absorbing portions 14, 14,.

  As the light-absorbing particles 16, 16,..., Light-absorbing colored particles such as carbon black are preferably used. However, the present invention is not limited to these, and a specific wavelength is selectively selected according to the characteristics of the image light. Absorbing colored particles may be used. Specific examples include organic fine particles colored with metal salts such as carbon black, graphite, and black iron oxide, dyes, pigments, colored glass beads, and the like. In particular, colored organic fine particles are preferably used from the viewpoints of cost, quality, availability, and the like. More specifically, acrylic cross-linked fine particles containing carbon black, urethane cross-linked fine particles containing carbon black, and the like are preferably used. Such colored particles are usually contained in the light absorbing part constituting composition in a range of 3% by mass to 30% by mass. The average particle diameter of the colored particles is preferably 1.0 μm or more and 20 μm or less. When forming the light absorbing portions 14, 14,..., As shown in FIG. 5 (a cross-sectional view schematically showing the step of forming the light absorbing portion), the light absorbing portion constituting composition containing colored particles. A step of scraping off an excess of the light absorbing portion constituent composition 46 using the doctor blade 47 while filling the object 46 in the grooves 13a, 13a,... Between the light transmitting portions 13, 13,. At this time, by using colored particles having an average particle diameter of 1.0 μm or more, it is possible to prevent the colored particles from easily passing through the gap between the doctor blade 47 and the light transmitting portions 13, 13,. The colored particles can be prevented from remaining on the portions 13, 13,.

  Also, depending on the material constituting the light transmission part, the surface of the light absorption part may be filled on the same plane (smooth) with respect to the surface of the light transmission part, or may be filled in a concave shape. is there.

  The means for absorbing light is not limited to the method using light absorbing particles as in this embodiment. Other examples include coloring the entire light absorbing portion with a pigment or dye.

  Next, a method for manufacturing the optical functional layer 12 will be described. FIG. 4 is a cross-sectional view schematically showing an example of a process for forming a light transmission part. FIG. 5 is a perspective view schematically showing an example of a process for forming the light absorbing portion.

  When the optical functional layer 12 is produced, as shown in FIG. 4, the light transmitting portions 13, 13,... Are formed on the base material 11 ′ that includes the layer that becomes the base material layer 11 or the base material layer 11. Form. In order to form the light transmitting portions 13, 13,..., First, a die roll 42 having grooves having a shape corresponding to the shape of the light transmitting portions 13, 13,. Next, the base material 11 ′ is fed between the mold roll 42 and the nip roll 41. The arrow x1 shown in FIG. 4 is the direction in which the substrate 11 'is fed. In accordance with the feeding of the base material 11 ′, the droplets of the light transmitting portion constituting composition 40 are continuously supplied from the supply device 45 between the mold roll 42 and the base material 11 ′. When the light transmitting portion constituting composition 40 is supplied from the supply device 45 onto the base material 11 ′, a bank in which the light transmitting portion constituting composition 40 is accumulated is formed between the mold roll 42 and the base material 11 ′. So that In this bank, the light transmitting portion constituting composition 40 spreads in the width direction of the base material 11 ′.

  The light transmitting portion constituting composition 40 supplied between the mold roll 42 and the base material 11 ′ as described above is formed by the pressing force between the mold roll 42 and the nip roll 41. It is filled between the rolls 42. Then, the light transmissive portions 13, 13... Can be formed by irradiating the light transmissive portion constituting composition 40 with ultraviolet rays or the like by the light irradiation device 44 and curing the light transmissive portion constituting composition. After the light transmitting portions 13, 13,... Are formed, the sheet on which the light transmitting portions 13, 13,. Torn off.

  Next, light absorbing portions 14, 14,... Are formed between the light transmitting portions 13, 13,... Of the sheet obtained through the process shown in FIG. Specifically, as shown in FIG. 5, the light absorbing portion constituting composition 46 is supplied onto the light transmitting portions 13, 13,..., And the light absorbing portion constituting composition 46 is transferred by the doctor blade 47. .., 13,..., While filling the grooves 13 a, 13 a,..., Scrape off the excess light absorbing portion constituent composition 46, and remain in the grooves 13 a, 13 a,. The light absorbing portions 14, 14,... Can be formed by irradiating the light absorbing portion constituting composition 46 with ultraviolet rays or the like to cure. In this way, the optical function layer 12 is formed on the base material layer 11. The arrow x2 shown in FIG. 5 is the sheet feeding direction obtained through the process shown in FIG.

  In the process shown in FIG. 5, the elastic modulus of the light transmitting portions 13, 13,... Is preferably 10 MPa or more and less than 2000 MPa. When the elastic modulus of the light transmitting portions 13, 13,... Is 2000 MPa or more, it becomes hard, causing defects such as cracks and chipping, and when forming the light absorbing portions 14, 14,. There is a possibility that an appearance defect may occur on the surface of the functional layer 12 or the transmittance of the optical functional layer 12 may be reduced. That is, when the light transmitting parts 13, 13,... Are too hard, when the doctor blade 47 scrapes off the surplus portion of the light absorbing part constituting composition 46 supplied onto the light transmitting parts 13, 13,. Are not deformed even if they are pressed against the light transmitting portions 13, 13,..., And therefore there is a possibility that the excess light absorbing portion constituting composition 46 cannot be scraped off. When the elastic modulus of the light transmitting portions 13, 13,... Is in the above range, when the doctor blade 47 is pressed, the excess light absorbing portion constituting composition 46 is scraped off due to the deformation of the light transmitting portions 13, 13,. Defects can be eliminated, and appearance defects on the surface of the optical function layer 12 can be prevented, and the transmittance of the optical function layer 12 can be prevented from decreasing. If the elastic modulus of the light transmission parts 13, 13,... Is 10 MPa or less, the light transmission parts 13, 13,... Are too soft, so that the light transmission parts 13, 13,. There is a risk that it will be difficult to release from the roll 42.

(Base material layer 11)
The base material layer 11 is a layer that becomes a base material for forming the optical functional layer 12 described above. As the base material layer 11, a material having translucency is used. As such a thing, films, such as a polycarbonate, a cycloolefin, and TAC (Triacetylcellulose (Triacetylcellulose)), can be mentioned, for example. Among these, polycarbonate is preferable from the viewpoint of availability, cost, and adhesiveness with the ionizing radiation curable resin (optical function sheet layer 12). The polycarbonate used herein is one having polycarbonate as a main polymer, and may include, for example, a filler such as a deterioration inhibitor, a plasticizer, and a softener, or a composite with a methacrylic resin or the like.

  Further, the surface of the base material layer 11 on the side where the optical functional layer 12 is formed may be subjected to primer treatment. The primer has a function of improving the adhesion between the base material layer 11 and the optical functional layer 12 during the manufacturing process of the transmissive curved screen and the use of the transmissive curved screen. As a method for applying the primer, known means such as a gravure coating method, a spray method, a roll coating method can be used. The primer coating thickness is not particularly limited as long as sufficient adhesion can be obtained between the base material layer 11 and the optical function layer 12, but is preferably about 1 μm or more and 10 μm or less. Known materials can be used as the primer material. For example, it consists of acrylic resin, polyvinyl resin, polyester, polyacrylate, polyurethane or a mixture thereof, each of which is dissolved and dispersed in a diluting solvent and then evaporating the diluting solvent, or by heat curing or ultraviolet curing The cured product can be used as a primer. Moreover, when making it harden | cure by an ultraviolet-ray, what is used without including a dilution solvent is also possible.

(Reinforcing layer 23)
The reinforcing layer 23 is a layer provided to suppress the deformation of the laminated body 10 and prevent the distortion of the image displayed by the transmissive curved screen provided with the laminated body 10. Therefore, it is preferable to design the material and thickness of the reinforcing layer 23 so as to give sufficient rigidity to the entire transmission type curved screen including the laminate 10. The thickness of the reinforcement layer 23 can be 3 mm or more and 5 mm or less, for example. If the reinforcing layer 23 is too thick, the thickness of the transmissive curved screen provided with the laminate 10 becomes too thick, the transmittance of the image light is reduced, and a ghost (double image) is generated. There is a fear.

  As the reinforcing layer 23, a material having translucency is used. Examples of such a material include methyl methacrylate / butadiene / styrene copolymer (MBS resin), methyl methacrylate / styrene copolymer (MS resin), acrylic resin, and polycarbonate resin. Among these, polycarbonate resin is preferable from the viewpoint of heat resistance and the like.

(Base material layer 24)
The base material layer 24 is a layer serving as a base material for forming a Fresnel lens layer 25 described later. As the base material layer 24, the thing similar to the base material layer 11 can be used.

(Fresnel lens layer 25)
The Fresnel lens layer 25 is a layer constituting a Fresnel lens by including a plurality of unit lenses. Examples of the resin constituting the Fresnel lens layer 25 include transparent resins such as acrylic resin, styrene resin, polyester resin, polycarbonate resin, and acrylic-styrene copolymer resin.

  The Fresnel lens layer 25 has a function of deflecting the traveling direction of the image light projected on the transmissive curved screen as a divergent light beam from the image light source. Specifically, the Fresnel lens layer 25 converts image light incident as a divergent light beam into a parallel light beam that travels from the image light source side toward the viewer side. In this way, once the image light is converted into a parallel light flux, variations in the brightness of the image observed from the viewer side can be reduced.

  The optical path of the image light incident on the Fresnel lens layer 25 will be described with reference to FIG. FIG. 6 is a diagram showing an optical path of image light incident on the Fresnel lens layer 25 while enlarging a part of the Fresnel lens layer 25.

  As shown in FIG. 6, the plurality of unit lenses 26 constituting the Fresnel lens layer 25 are observed by making the incident surface 27 that refracts and enters the image light L and the image light L incident from the incident surface 27 totally reflected. And a total reflection surface 28 directed toward the person side. As described above, the image light L emitted from the image light source is projected as a divergent light beam onto the transmissive curved screen, enters the Fresnel lens layer 25, and is refracted and reflected by the unit lens 26 constituting the Fresnel lens layer 25. As a result, the light is converted into a parallel light beam and emitted to the optical functional layer 12 side.

  Examples of the unit lens 26 constituting such a Fresnel lens layer 25 will be described below. 7 to 9 are plan views schematically showing the Fresnel lens layer 25. FIG. 7 and 8 represent so-called circular Fresnel lenses, and FIG. 9 represents a so-called linear Fresnel lens. 7 to 9, the back of the paper is the observer side, and the front of the paper is the video light source side. Further, the “horizontal direction” shown in FIGS. 7 to 9 is a horizontal direction when the laminated body 10 is provided in the display device, and the “vertical direction” is provided in the display device with the laminated body 10. It is the direction that is vertical when

  Unit lenses 26a, 26a,... Constituting the Fresnel lens layer 25a shown in FIG. 7 are arranged so as to extend on arcs of concentric circles. Further, the configuration of the unit lenses 26a, 26a,... In the horizontal direction is line symmetric with respect to an axis Aa parallel to the vertical direction passing through the center position in the horizontal direction. Such a configuration of the unit lenses 26a, 26a,... Can be designed based on the arrangement of the image light source and the like with respect to the transmissive curved screen. For example, the center O of the concentric circle related to the arrangement of the unit lenses 26a, 26a,... Is designed so as to overlap with the arrangement position of the video light source when a display device including a transmissive curved screen is observed from the front. In this case, the center O may be called the optical center of the Fresnel lens layer 25a. In this way, by decentering the center O from the center of the Fresnel lens layer 25a vertically downward, even if image light is projected from below the transmissive curved screen, the divergent light beam from the image light source is converted into a parallel light beam. Can do. By adopting a configuration in which the image light is irradiated from below the transmissive curved screen, the thickness of the display device including the transmissive curved screen can be reduced.

  The Fresnel lens layer 25b shown in FIG. 8 differs from the Fresnel lens layer 25a shown in FIG. 7 in the position of the center O of the concentric circle with respect to the arrangement of the unit lenses 26b, 26b,. Like the Fresnel lens layer 25b shown in FIG. 8, the center O of the concentric circle related to the arrangement of the unit lenses 26b, 26b,...

  The unit lenses 26c, 26c,... Constituting the Fresnel lens layer 25c shown in FIG. 9 extend linearly in the horizontal direction, and the unit lenses 26c, 26c,. In this way, the unit lenses 26c, 26c,... Can be so-called linear Fresnel lenses. However, in the case of the linear Fresnel lens, the light can be converged in the arrangement direction of the unit lenses (in the form shown in FIG. 9, the vertical direction on the paper surface), but the direction in which the unit lens extends (in the form shown in FIG. (Direction) cannot converge light.

  A method for forming such a Fresnel lens layer is not particularly limited. For example, the Fresnel lens layer 25 can be formed by forming the unit lenses 26, 26,... On the base material layer 24 in the same manner as the light transmitting portions 13, 13,.

  FIG. 2 illustrates a form in which the Fresnel lens layer 25 is formed on the base material layer 24 and the base material layer 24 and the reinforcing layer 23 are laminated via the pressure-sensitive adhesive layer 22c. Is not limited to such a form. FIG. 10 is a diagram schematically showing a part of a cross section of another example of the laminate produced in step S11. In FIG. 10, the same components as those shown in FIG. As in the laminated body 10 ′ shown in FIG. 10, the Fresnel lens layer 25 can be formed on the image light source side of the reinforcing layer 23. In this case, for example, the Fresnel lens layer 25 can be formed by forming the unit lenses 26, 26,... On the reinforcing layer 23 in the same manner as the light transmitting portions 13, 13,.

(Adhesive layers 22a, 22b, 22c)
In step S11, the layers constituting the laminate are fixed to each other by fusion or via an adhesive layer. In the form shown in FIG. 2, the light diffusion layer 21 and the optical functional layer 12 are laminated via the pressure-sensitive adhesive layer 22a, and the base material layer 11 and the reinforcing layer 23 are laminated via the pressure-sensitive adhesive layer 22b. The reinforcing layer 23 and the base material layer 24 are laminated via the adhesive layer 22c. The pressure-sensitive adhesive layers 22a, 22b, and 22c are layers containing a pressure-sensitive adhesive, and the material of the pressure-sensitive adhesive is not particularly limited as long as it transmits light and has appropriate adhesiveness. Examples thereof include an acrylic pressure-sensitive adhesive. The adhesive force is, for example, about several N / 25 mm to 20 N / 25 mm.

(Other layers)
In this invention, the laminated body 10 produced by process S11 should just be provided with the light-diffusion layer 21 at least, and does not necessarily require all the layers demonstrated so far. Moreover, the laminated body 10 can be appropriately provided with layers provided in a conventional transmission type screen in addition to the layers exemplified so far. Examples of the layer provided in the conventional transmission screen include a layer that can diffuse or collect light by arranging a plurality of transparent spheres and lenses on a transparent substrate.

<First curved surface forming step S12>
The first curved surface forming step S12 (hereinafter sometimes simply referred to as “step S12”) is a step of bending the flat laminate produced in step S11 so as to form a three-dimensional curved surface.

  FIG. 11 is a perspective view schematically showing the appearance of the laminated body 10 bent so as to form a three-dimensional curved surface in step S12. In FIG. 11, the back side of the paper is the image light source side (light incident surface side), and the front side of the paper is the observer side (light exit surface side). Further, the “horizontal direction” shown in FIG. 11 is a horizontal direction when the stacked body 10 is provided in the display device, and the “vertical direction” is provided in the display device. In this case, the direction is vertical.

  As shown in FIG. 11, the laminated body 10 is formed so as to form a three-dimensional curved surface that is convex toward the viewer. Here, “formed so as to form a three-dimensional curved surface” means that it is bent partially or entirely around a plurality of axes inclined with respect to each other. Specifically, the laminated body 10 has a rectangular shape when formed into a flat plate shape, and is centered on a first axis A1 that is parallel to one diagonal line of the rectangular shape and located on the video light source side of the laminated body 10. And is also bent in a direction d2 centered on a second axis A2 that is located on the video light source side of the laminate 10 and is parallel to the other diagonal line and intersects the first axis A1. As a result, the laminated body 10 is formed so as to form a three-dimensional curved surface that is convex toward the viewer as a whole. Moreover, the display surface 10a of the laminated body 10 protrudes most to the viewer side at a central position Pa where a pair of rectangular diagonal lines when the laminated body 10 is formed into a flat plate shape.

  However, the shape of the transmissive curved screen that can be manufactured by the transmissive curved screen manufacturing method of the present invention is not limited to the shape shown in FIG. By appropriately changing the mold used for molding, it is possible to manufacture a transmissive curved screen so as to form various three-dimensional curved surfaces. Moreover, the shape when the transmission type curved screen is formed into a flat plate is not limited to a rectangle, and various shapes can be obtained by appropriately cutting before or after molding.

  Step S12 will be described with reference to FIGS. 12 and 13 and the drawings shown as appropriate, taking the case of using the laminate 10 as an example. 12 and 13 are cross-sectional views schematically showing an example of step S12. As will be described below, the step S12 is preferably a step of heating the laminate 10 and vacuum-forming or vacuum-forming the laminate 10 using a mold that can obtain a desired shape. Moreover, when the laminated body 10 does not have a Fresnel lens layer, the laminated body 10 may be heated, and the laminated body 10 may be closely attached to a mold using a pressing member. The temperature at which the laminated body 10 is heated in step S12 is a glass transition temperature Tg (a glass transition temperature of a layer having the highest glass transition temperature among the layers constituting the laminated body 10) or higher, for example, 120 ° C. or higher and 180 ° C. or lower. Preferably there is.

  FIG. 12 illustrates a case where a female mold 50 having a bowl-shaped recess 55 and a flat portion 52 surrounding the periphery is used. When the laminated body 10 is molded by the mold 50, first, the laminated body 10 is placed on the mold 50 as shown in FIG. At this time, the surface on the image light source side of the laminate 10 is set to the upper side (the side opposite to the mold 50). Thereafter, as shown in FIG. 12B, the flat portion 52 of the mold 50 and the laminate 10 are brought into contact with each other. Then, as shown in FIG. 12 (c), by applying air pressure from above the laminate 10 and / or evacuating from the holes 51, 51,... Provided in the mold 50, The mold 50 is brought into close contact. Thus, the laminated body 10 can be shape | molded.

  FIG. 13 illustrates a case where a male die 60 having a convex portion 65 having a shape corresponding to the concave portion 55 of the die 50 shown in FIG. 12 and a flat portion 62 surrounding the periphery thereof is used. When the laminated body 10 is molded by the mold 60, first, the laminated body 10 is disposed on the mold 60 as shown in FIG. At this time, the surface on the image light source side of the laminate 10 is set to the lower side (the mold 60 side). Thereafter, as shown in FIG. 13 (b), the top portion 64 of the convex portion 65 and the laminate 10 are brought into contact with each other. Thereafter, by applying air pressure from above the laminate 10 and / or evacuating from the holes 61, 61,... Provided in the mold 60, as shown in FIG. The mold 60 is brought into close contact. Thus, the laminated body 10 can be shape | molded.

  In the case of using a female mold as shown in FIG. 12 and the case of using a male mold as shown in FIG. Is preferred.

  When using the mold 50, the holes 51, 51,... Are provided in the flat portion 52 and the bottom portion 54 of the recess 55 from the viewpoint of efficiently performing vacuuming. Further, as described above, when the laminate 10 and the mold 50 are brought into close contact with each other, the laminate 10 is first subjected to pressure after contacting the flat portion 52. At this time, the end portion of the concave portion 55, that is, the portion of the laminated body 10 that is in contact with the boundary 53 between the concave portion 55 and the flat portion 52 is hardly deformed. On the other hand, the portion of the laminate 10 that is in close contact with the bottom 54 is most easily deformed and becomes thinner. The portion of the laminate 10 that is in close contact with the bottom 54 is a portion that becomes the center of the screen 10, and it is preferable that the deformation is small. This is because if the portion becomes thinner, the brightness and viewing angle of the image may be greatly affected.

  On the other hand, when the mold 60 is used, the holes 61, 61,... Are provided in the flat portion 62 from the viewpoint of efficiently performing vacuuming. Further, as described above, when the laminate 10 and the mold 60 are brought into close contact with each other, the laminate 10 is first subjected to pressure after contacting the top portion 64. At this time, the portion of the laminate 10 that is in contact with the top 64 is difficult to deform. As described above, it is preferable that the portion is less deformed. As described above, the molding using the male mold can suppress that the central portion of the screen is thinner than the other portions when the laminate 10 is used for the transmissive curved screen. Therefore, it is preferable.

  In the description of step S12 so far, the method of heating the laminate 10 and molding the laminate 10 by vacuum forming, pressure forming, or vacuum / pressure forming has been described. However, the present invention is not limited to such a form. . Step S12 may be a step of heating the laminate 10 and molding the laminate 10 by press molding, for example.

  However, when the laminate 10 includes the Fresnel lens layer 25, it is preferable to perform vacuum molding, pressure molding, or vacuum / pressure molding using a female mold. As described above, when the laminate 10 is molded using the mold 60, the laminate 10 is arranged and molded so that the surface on the video light source side is on the lower side (the mold 60 side). Since the Fresnel lens layer 25 is provided on the image light source side of the laminate 10, when a male type is used, there is a possibility that the Fresnel lens layer 25 may be crushed by being pressed by the mold when molding. Even when press molding is performed, the Fresnel lens layer 25 may be crushed by being pressed by the mold.

  In the description of step S12 so far, the description has been made with reference to the sectional view of the mold. However, when the mold is viewed three-dimensionally, it is preferable to use a mold as described below.

  FIG. 14A is a perspective view of the mold 140. In FIG. 14 (a), the hatched portion is where the portion of the laminate 10 that will ultimately be used for the transmissive curved screen is placed during molding. FIG. 14B is a cross section taken along line XIVb-XIVb shown in FIG. In the mold 140 shown in FIG. 14, a concave portion 141 is formed in accordance with a portion of the laminate 10 that is finally used for a transmissive curved screen. Therefore, as shown in FIG. 14B, there is no step in the longitudinal direction of the concave portion 141, but as shown in FIG. 14C, the flat portion 142 and the concave portion are formed in the short direction of the concave portion 141. Steps 143 and 143 are formed between the first step 141 and the second step 141. When there is such a step, when the laminate 10 is molded, the laminate 10 is stretched more than other portions at the step portion, so that the laminate 10 is likely to crack. Therefore, it is preferable to use the mold 150 shown in FIG. 15 or the mold 160 shown in FIG. 16 as a mold for preventing the occurrence of such cracks.

  FIG. 15A is a perspective view of the mold 150. In FIG. 15A, the hatched portion is a place where a portion of the laminate 10 that is finally used for the transmissive curved screen is disposed when molding. FIG. 15B is a cross section taken along line XVb-XVb shown in FIG. In FIG. 15B, L3 indicates the width of the portion of the laminated body 10 that is finally used for the transmissive curved screen during molding. L4 indicates the width of the portion between the portions indicated by L3 and L3, that is, the portion that is not used in the transmissive curved screen and is discarded. FIG. 15C is a cross section taken along line XVc-XVc shown in FIG. In FIG. 15C, L5 indicates the width of the portion of the laminate 10 that is finally used for the transmissive curved screen when being molded. L6 indicates the width between the portions indicated by L5 and L5, that is, the width of the portion that is not finally used in the transmissive curved screen and is discarded.

  The mold 150 includes a molding part 151 formed of an elliptical or circular concave part in plan view, and the molding part 151 is used for molding the laminated body 10. By forming the molding portion 151 with a concave portion that is oval or circular in plan view, the step between the molding portion 151 and the flat portion 152 can be eliminated. That is, in any cross-sectional view of the mold 150 in the thickness direction, the molded part 151 is formed by a single curve having no corners, and the molded part 151 and the flat part 152 form an obtuse angle. Therefore, the use of the mold 150 can prevent the occurrence of cracks as described above when the laminate 10 is molded. In addition, the mold 150 has a plurality of molding parts 151, and multi-faceting is possible by cutting the laminate 10 into an appropriate size after the step S11. The number of molding parts 151 provided in the mold 150 is not particularly limited. The mold 150 is a so-called female mold in which the molding portion 151 is formed of a concave portion. However, even if a so-called male die having a convex portion having a shape corresponding to the molding portion 151 as a molding portion is used, the laminate 10 is similarly formed. It is possible to prevent cracks from occurring.

  Thus, from the viewpoint of preventing cracks from occurring in the laminated body 10 in the step S12, it is preferable to use a mold having a molding part composed of an elliptical or circular convex part or a concave part in plan view.

  However, since the screen is usually rectangular in a plan view, the mold 10 such as the mold 150 wastes the stacked body 10. That is, as shown in FIG. 15C, it is possible to minimize the useless portion L6 on the longitudinal side of the transmissive curved screen, but the transmissive curved screen is rectangular in plan view. For this reason, as shown in FIG. 15B, the useless portion L4 increases on the side of the transmissive curved screen in the short direction. From the viewpoint of reducing such waste, it is preferable to use a mold such as the mold 160 shown in FIG.

  FIG. 16A is a perspective view of the mold 160. In FIG. 16A, the hatched portion is a place where a portion of the laminated body 10 that is finally used for the transmissive curved surface screen is disposed during molding. FIG. 16B is a cross section taken along line XVIb-XVIb shown in FIG. In FIG. 16B, L7 indicates the width of the portion of the laminate 10 that is finally used for the transmissive curved screen during molding. L8 indicates the width of the portion between the portions indicated by L7 and L7, that is, the portion that is not used in the transmissive curved screen and is discarded.

  The mold 160 includes a molding part 161 formed of an elliptical or circular recess in plan view, and the molding part 161 is used for molding the laminate 10. In addition, the mold 160 includes at least one row in which a plurality of molding portions 161 are arranged (two rows are provided in the form shown in FIG. 16). It is formed so that a part of each other overlaps. That is, the half of the length L9 of the line segment connecting the center P of one molding part 161 adjacent in the row and the center P of the other molding part 161 is the center of the molding part 161 located at the end most in the row. It is shorter than the distance L10 from P to the end on the side where no other molding part 161 exists. The center P means the deepest position of the molding part 161.

  In this way, by providing the molding portion 161 so that the direction corresponding to the short direction of the transmissive curved screen is shortened, the wasted portion L8 can be reduced as shown in FIG. it can. The number of molding parts 161 provided in the mold 160 is not particularly limited. In addition, the mold 160 is a so-called female mold in which the molding portion 161 is configured by a concave portion. However, even if a so-called male die having a convex portion having a shape corresponding to the molding portion 161 as a molding portion is used, the laminate 10 is similarly formed. It is possible to prevent cracks from occurring and to reduce the portion of the laminate 10 that is wasted.

  The depth (in the case of using a female type) or the height (in the case of using a male type) of the mold used in step S12 can be appropriately changed according to the use of the transmissive curved screen provided with the laminate 10.

  After the laminated body 10 is molded in step S12 as described above, a structure obtained by appropriately cutting the laminated body 10 to obtain an appropriate shape can be used for a transmissive curved screen.

1.2. Second Embodiment Next, a method for manufacturing a transmissive curved screen according to the second embodiment of the present invention will be described. FIG. 17 is a flowchart showing steps included in the method of manufacturing a transmissive curved screen according to the second embodiment of the present invention. The manufacturing method of the transmissive curved screen of the present invention shown in FIG. 2 includes a step S11, a step S12, a Fresnel lens sheet manufacturing step S21, a second curved surface forming step S22, and a laminating step S23. Hereinafter, the process shown in FIG. 17 will be described. Since Step S11 and Step S12 are as described above, description thereof is omitted.

<Fresnel lens sheet manufacturing step S21>
The Fresnel lens sheet manufacturing step S21 (hereinafter sometimes simply referred to as “step S21”) is a step of manufacturing a Fresnel lens sheet having a Fresnel lens layer. The configuration of the Fresnel lens layer can be the same as that of the Fresnel lens layer 25 described in the description of the first embodiment. The Fresnel lens sheet can be produced by forming the Fresnel lens layer 25 on the base material layer. As the base material layer, for example, a base material made of methyl methacrylate / butadiene / styrene copolymer (MBS resin), methyl methacrylate / styrene copolymer (MS resin), acrylic resin, polycarbonate resin or the like can be used. .

  The thickness of the base material layer used for the Fresnel lens sheet can be, for example, 1 mm or more and 3 mm or less. If the base material layer is too thin, it is difficult to give the Fresnel lens sheet sufficient strength, and if the base material layer is too thick, when used for a transmissive curved screen, the transmittance of image light decreases. There is a risk that a ghost (double image) may occur.

<Second curved surface forming step S22>
The second curved surface forming step S22 (hereinafter sometimes simply referred to as “step S22”) is a step of bending the Fresnel lens sheet produced in step S21 so as to form a three-dimensional curved surface.

  As a method of bending the Fresnel lens sheet so as to form a three-dimensional curved surface, the same method as in step S12 described above can be used. However, since the thickness of the laminate that is bent in step S12 and the Fresnel lens sheet that is bent in step S22 are different from each other, an extra gap is prevented when the laminate and the Fresnel lens sheet are laminated after being bent. Needs to be molded using a mold that takes into account the thickness difference between the laminate and the Fresnel lens sheet. In addition, in order to prevent the Fresnel lens layer provided in the Fresnel lens sheet from being crushed, as described above, molding using a male mold or press molding is not suitable for step S22.

  According to the method for manufacturing a transmissive curved screen of the present invention according to the second embodiment, since the Fresnel lens sheet and the laminate are separately molded, the laminate can be molded in a male shape. As described above, in the step S12, it is preferable to use a male type. However, when the laminate is provided with a Fresnel lens layer, the laminate cannot be molded using the male type. According to the method for manufacturing a transmissive curved screen of the present invention according to the second embodiment, a laminated body can be molded in a male shape in step S12, and a Fresnel lens layer can be provided on the transmissive curved screen. .

<Lamination process S23>
The lamination step S23 (hereinafter may be simply referred to as “step S23”) is produced in step S22 on the light incident surface side of the laminate produced in step S12 and bent to form a three-dimensional curved surface. This is a step of laminating the Fresnel lens sheets bent so as to form a three-dimensional curved surface. In addition, before laminating | stacking a laminated body and a Fresnel lens sheet, you may cut each to an appropriate magnitude | size.

  The method for laminating the laminate and the Fresnel lens sheet is not particularly limited. For example, the base material layer of the Fresnel lens sheet and the surface on the light incident surface side of the laminate can be bonded and laminated by the same layer as the pressure-sensitive adhesive layer described above.

  It is also possible to laminate the Fresnel lens sheet and the laminate with the Fresnel lens layer of the Fresnel lens sheet facing the laminate. However, note the following points in this case. That is, since the Fresnel lens layer may be rubbed against the laminated body and the laminated body may be wrinkled, it is preferable to apply silicone oil or the like to the surface of the laminated body that contacts the Fresnel lens layer. In addition, if the gap between the Fresnel lens layer and the laminate becomes large, a ghost (double image) may occur when used in a transmissive curved screen, so that the laminate and the Fresnel lens layer are brought into contact with each other. It is preferable to keep it. Thus, the method of laminating the Fresnel lens sheet and the laminate is not particularly limited. For example, there is a method in which a Fresnel lens sheet and a laminate are stacked and their peripheral parts are sandwiched and fixed by a metal clip.

  As described above, the laminate produced in step S12 and bent to form a three-dimensional curved surface and the Fresnel lens sheet produced in step S22 and bent to form a three-dimensional curved surface are laminated. After that, the structure obtained by appropriately cutting to obtain an appropriate shape can be used for a transmissive curved screen.

  As described so far, according to the method of manufacturing a transmissive curved screen of the present invention, it is possible to easily manufacture a transmissive curved screen having improved design by forming a three-dimensional curved surface. it can. Such a transmissive curved screen with improved design can be suitably used for parts where design is very important, such as automobile dashboards and amusement equipment. In addition, according to the method of manufacturing a transmissive curved screen of the present invention, by molding by the method illustrated, the pressure applied to the mold is lower than when performing injection molding, so compared to injection molding, The mold to be used can be manufactured at low cost. That is, according to the method of manufacturing a transmissive curved surface screen of the present invention, it is possible to use a mold composed of wood, synthetic wood, gypsum, etc., and even when using a mold, it is stronger than a mold used for injection molding. Therefore, the initial cost for manufacturing the transmissive curved screen can be reduced.

2. Next, a method for manufacturing a display device according to the present invention will be described.

  A manufacturing method of a display device of the present invention is a transmissive curved screen including a laminate that can transmit video light incident from the light incident surface side to the light output surface side and is bent so as to form a three-dimensional curved surface, An image display device manufacturing method comprising: an image light source that emits image light; and a housing that supports the transmissive curved screen and accommodates the image light source. FIG. 18 is a diagram schematically showing a cross section of an example of a display device manufactured by the display device manufacturing method of the present invention.

  Taking the display device 1 shown in FIG. 18 as an example, a method for manufacturing a display device of the present invention will be described. The display device 1 can be manufactured by arranging the video light source 3 and the like in the housing 2 and then supporting the transmissive curved screen 100 in the opening of the housing 2. The transmissive curved screen 100 can be manufactured by the above-described transmissive curved screen manufacturing method of the present invention. As the housing 2 and the image light source 3, those used in a display device having a conventional transmissive screen can be used without any particular limitation.

  As described above, the manufacturing method of the display device according to the present invention includes the step of producing the transmissive curved screen by the method of manufacturing the transmissive curved screen of the present invention, the image light source, and the transmissive curved screen incorporated in the casing. And a process.

  According to the method of manufacturing a transmissive curved screen of the present invention, a transmissive curved screen having improved design can be easily manufactured by forming a three-dimensional curved surface. According to this manufacturing method, it is possible to easily manufacture a display device provided with a transmissive curved screen with improved design by forming a three-dimensional curved surface.

  Although FIG. 18 illustrates a mode in which the video light L from the video light source 3 is directly applied to the transmissive curved screen 100, the present invention is not limited to such a mode. For example, like the display device 1 ′ shown in FIG. 19, the image light L from the image light source 3 is irradiated onto the mirror 4 provided in the housing 2 ′, and the reflected light L ′ is irradiated to the transmissive curved screen 100. It is good also as a form which irradiates. FIG. 19 illustrates an example in which the image light L is reflected once by a single mirror 4, but the number of mirrors provided in the housing is not particularly limited, and a plurality of mirrors are used to reflect the light several times. It is also possible to irradiate the transmissive curved screen 100 with image light. If the image light is thus reflected and applied to the transmissive curved screen 100, the depth of the housing can be reduced.

DESCRIPTION OF SYMBOLS 1, 1 'Display apparatus 2, 2' Case 3 Image | video light source 4 Mirror 10 Laminated body 10a Display surface 11 Base material layer 12 Optical function layer 13 Light transmission part 14 Light absorption part 15 Binder 16 Light absorption particle 20 Hard coat layer 21 Light diffusion layer 22a, 22b, 22c Adhesive layer 23 Reinforcement layer 24 Base material layer 25 Fresnel lens layer 26 Unit lens 27 Incident surface 28 Total reflection surface 50 Female type 60 Male type 100 Transmission type curved screen 150, 160 type 151, 161 Molding part

Claims (11)

A method of manufacturing a transmissive curved screen comprising a laminate that is capable of transmitting image light incident from the light incident surface side to the light exit surface side and is bent so as to form a three-dimensional curved surface,
A laminate production step of producing the laminate in a flat plate shape;
A first curved surface forming step of bending the flat plate-shaped laminated body produced in the laminated body production step so as to form a three-dimensional curved surface,
A method for manufacturing a transmissive curved screen, wherein the laminate includes a light diffusion layer capable of diffusing the image light to be emitted.   The laminated body manufacturing step includes an optical function layer having a light transmission part arranged in parallel along a sheet surface so as to transmit light, and a light absorption part arranged in parallel so as to absorb light between the light transmission parts The manufacturing method of the transmissive | pervious curved screen of Claim 1 including the process to form.   The manufacturing method of the transmissive | pervious curved screen of Claim 1 or 2 which heats the said laminated body and performs vacuum forming, pressure forming, or vacuum / pressure forming in the said 1st curved surface formation process.   The first curved surface forming step is a step of bending the laminated body so as to form a three-dimensional curved surface using the molded portion of a mold provided with a molded portion composed of an elliptical or circular convex portion or concave portion in plan view. The manufacturing method of the transmissive | pervious curved screen in any one of Claims 1-3. The mold used in the first curved surface forming step is
It has at least one row in which a plurality of the molding parts are arranged,
The manufacturing method of the transmissive | pervious curved screen of Claim 4 currently formed so that the said shaping | molding part adjacent in the said row | line | column may mutually overlap in planar view.   The method for manufacturing a transmissive curved screen according to any one of claims 1 to 5, wherein the laminate manufacturing step includes a step of forming a Fresnel lens layer on the most light incident surface side of the laminate. Creating a Fresnel lens sheet having a Fresnel lens layer;
A second curved surface forming step of bending the Fresnel lens sheet to form a three-dimensional curved surface;
The laminated body produced in the first curved surface forming step and bent to form a three-dimensional curved surface is bent to form the three-dimensional curved surface produced in the second curved surface forming step on the light incident surface side. And laminating the Fresnel lens sheet,
The manufacturing method of the transmissive | pervious curved screen in any one of Claims 1-5 containing these.   The method of manufacturing a transmissive curved screen according to claim 7, wherein in the second curved surface forming step, the Fresnel lens sheet is heated to perform vacuum molding, pressure molding, or vacuum / pressure molding.   The step of forming the second curved surface is a step of bending the Fresnel lens sheet so as to form a three-dimensional curved surface using the molded portion of the mold having an elliptical or circular convex portion or concave portion in plan view. The manufacturing method of the transmissive | pervious curved screen of Claim 7 or 8 which is these. The mold used in the second curved surface forming step is
It has at least one row in which a plurality of the molding parts are arranged,
The method of manufacturing a transmissive curved screen according to claim 9, wherein the molding parts adjacent in the row are formed so as to partially overlap each other in plan view. A transmissive curved screen comprising a laminate that can transmit image light incident from the light incident surface side to the light output surface side and is bent so as to form a three-dimensional curved surface, an image light source that emits the image light, A housing for supporting the transmissive curved screen and housing the video light source,
A step of producing the transmissive curved screen by the method of manufacturing a transmissive curved screen according to any one of claims 1 to 10,
Incorporating the image light source and the transmissive curved screen into the housing;
A method for manufacturing a display device.

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