1248551 (1) 九、發明說明 [發明所屬之技術領域】 本發明是關於實投影顯示器用屏幕之微透鏡陣列片之 製造方法，特別是關於已提昇對比度的實投影顯示器用屏 幕之微透鏡陣列片之製造方法。 【先前技術】 於一般，實投影顯示裝置主要是由3種類的零件：爲 · 圖像生成零件的顯示機器；可使顯示機器所射出的圖像光 投影在投影用屏幕上的光學系統；及，可接受圖像光的投 影用屏幕所構成。 _ 這當中位於最接近觀察者位置的投影用屏幕是由2種 . 類的光學構件所構成，這些於一般從顯示機器側開始依序 是稱爲菲涅耳透鏡及雙凸透鏡板。菲涅耳透鏡的功能是圖 像光整體的平行校正，雙凸透鏡板的功能是各個畫素射出 畫素光的擴散角調節。 Φ 此外，大多數的屏幕，從雙凸透鏡板看是於觀察者側 配置著設有反射防止膜的前面板。當雙凸透鏡板是露出在 最前面時，接觸等其他因素會造成雙凸透鏡板變形使圖像 扭曲，不受歡迎，但並非本質性問題。 當顯不機器所射出的圖像光到達投影用屏幕時，因由 光學系統會進行放大使投影用屏幕的有效顯示區域上具有 一致的剖面’所以來自於顯示機器的光束會朝觀察者方向 擴散，但並不是各晝素所射出的圖像光全部都朝同一方向 -6- (2) (2)1248551 擴散。因所射出的圖像光的強度最大方向是每個畫素有所 不同’所以在使用未具有圖像光擴散角調節功能的投影用 屏幕時’對不管在任何方向看的觀察者而言都無法顯示出 整個顯示畫面全體爲同一的顯示品質。這是因爲每個畫素 的視角-亮度分佈特性有所不同。 然而，在資料顯示的設計思想上，例如就電腦銀幕而 言是需要有對於從有效視野角範圍看的任何觀察者都能顯 示出整個顯示畫面全體爲同一的顯示品質的功能。因此畫 面構成用的所有畫素所射出的各個畫素光的強度在其有效 視野角內都需擴散成於任一射出角方向均爲同一強度。爲 使用如此擴散面的狀況時，對於位在有效視野角範圍內外 邊界部的觀察者而言只要稍微移動視點就會看到顯示品質 的急遽變化，但本質上因使用者即觀察者是爲一人所以不 成問題。 此外，也有顯示品質最好是能夠因有效視野角範圍內 的觀察者位置而逐漸變化的設計思想，這是在多數人使用 的狀況，即是應用在電視機。大多數的狀況是設計成從正 面即視角（屏幕面垂直線與觀察者視線形成的角度）=0 看時的亮度爲最大而隨著視角逐漸傾斜會逐漸降低亮度的 擴散模式。現在市面上看得到的投影顯示器大多數是針對 該特性來設計的。於該狀況也是相同需要將來自於所有晝 素的射出光都爲同一擴散模式。 爲了使投影用屏幕上的所有畫素所射出的各個畫素光 的擴散模式爲同一模式，必須使用光學系統對來自於顯示 (3) (3)1248551 機器利用放大光學系統以各種入射角度到達投影用屏幕分 別具有不同光度角度分佈的各個畫素光進行校正。即，在 投影用屏幕面的各畫素所對應的各位置上設置光軸（最大 光度顯示方向）和擴散角校正用的微透鏡就能夠達成上述 目的。 但是，因要正確地將微透鏡配置在投影用屏幕面上的 多數晝素所對應的位置是需要極精密的定位操作，所以在 該設備上需要高額的費用，因生產性低所以製造成本就變 龐大。此外，這樣的微透鏡陣列因是針對特定的光學系統 和顯示機器的組合來設計的所以不具通用性會導致製造成 本增加。 因此，爲了避免進行顯示機器側的畫素和投影用屏幕 面上的畫素的定位操作，於一般上是把要配置在投影用屏 幕面上的微透鏡分割成複數。 此時’若把要配置在投影用屏幕面上的微透鏡的間距 爲畫素間距的1 /5以下時則即使產生某程度的位置偏差也 不會造成有眼睛看得到的析像度降低。 另一方面’因要對來自於投影用屏幕上各畫素射出光 的光軸和擴散角校正用的微透鏡進行分別設計製造是件極 繁雜並且困難的事，所以現在所採用的方法是一旦平行校 正後就將朝屏幕的入射光整體轉換成平行光於微透鏡陣列 是不進行光軸校正的方法。 即，在投影用屏幕的光學機器側首先是配置做爲第一 光學構件的菲涅耳透鏡進行平行校正，將菲涅耳透鏡所射 -8- (4) (4)1248551 出來的平行光擴散角在微透鏡陣列進行校正。因入射至微 透鏡陣列的圖像光是爲平行光所以使射出光成爲具有角度 分佈地來擴散（即擴散角校正）是微透鏡陣列最重要的功 能。角度分佈是以微透鏡陣列構成用的單位胞曲面形狀來 決定。 以上，就現在而言投影顯示器用屏幕的全部是採用上 述構成。 擴散微透鏡陣列在大多數的狀況雖是使用僅於一軸方 向具有聚光作用的柱面透鏡陣列，但也可使用於二軸以上 的方向具有聚光作用的蠅眼透鏡。此外，也可局部使用是 採用並列著微小球的球透鏡陣列。 如上述，微透鏡於一般主要是爲具圖像光擴散功能的 構件，但因是爲配置在最前面的構件所以更要有極重要的 特性要求。即，是爲顯示器重要的顯示品質項目的對比度 。對比度愈高則顯示品質愈良好。爲要提高對比度在提昇 點燈時的亮度的同時需要降低非點燈時的亮度。 因此就有必要將屏幕表面形成爲黑色，但在圖像光通 過的路徑途上配置有黑色物時該黑色物會吸收圖像光，造 成亮度降低所以只能在圖像光不通過的部份配置黑色物， 因此’至少圖像光通過路徑的相當部份是無法形成爲黑色 。如此一來，如何使屏幕上圖像光不通過的部份是爲最大 面積比率就成爲在非點燈時的亮度降低上應該解決的課題 〇 圖像光在屏幕表面附近的舉動如下述。首先，顯示機 -9 - (5) (5)1248551 器所射出的圖像光是邊放射狀擴散邊到達反射鏡’然後入 射至屏幕。此時圖像光最先通過的是菲捏耳透鏡’由菲捏 耳透鏡的平行校正功能使圖像光轉換成大致平行光。所謂 大致平行光，並非只完全平行的光而是指平行度有某種程 度偏離平行的平行光。其原因在於菲涅耳透鏡這種透鏡本 身並未完全具有所期望的功能。 如第1圖所示由菲涅耳透鏡A平行校正後的圖像光B 其次是入射至微透鏡陣列C，但這是由各個小晶狀體（微 透鏡陣列構成用的單一微透鏡）的聚光作用成爲各個聚光 。因此，在屏幕面上入射光是於每個小晶狀體通光焦點。 當微透鏡陣列是爲柱面透鏡陣列時焦點是形成爲線狀，而 蠅眼透鏡的狀況是形成爲點的配列。爲使包括該焦點全部 在內的面即焦點面與形成有微透鏡陣列的基板的該微透鏡 陣列所形成的面爲相反的面可成爲一致是有必要決定基板 厚度和微透鏡陣列焦點距離的關係。 於上述的焦點面上圖像光是僅通過焦點。雖於實際上 因製作精度或小晶狀體的聚光特性、像差等使焦點具有某 種程度的寬幅，但幾乎是聚光於一點，所以焦點面內的焦 點以外部份的占有比率極高。若能夠使該部份被覆著黑色 材料則可獲得黑色化率高的畫面。 要使焦點面內的焦點部份保有完全穿透狀態的同時使 這以外的部份被覆著黑色材料是需要有獨特的竅門。由黑 色材料形成的膜雖必須對準所要覆蓋側的模樣即微透鏡陣 列的小晶狀體，但小晶狀體的間距是爲30〜200μηι程度， -10- (6) (6)1248551 焦點的大小雖也要視小晶狀體的特性而定但通常是爲小晶 狀體間距的1 /5程度所以是爲6〜4 Ο μπι程度。爲了使只有 這樣微小的區域不附著黑色材料只於其他部份附著黑色材 料’通常是採用掩模曝光造成的光化學反應。 然而，要覆蓋黑色材料的微透鏡陣列及形成有該微透 鏡陣列的基板是爲塑膠製，其不具有能夠應對於需要如此 高精度定位作業流程的尺寸精度及尺寸穩定性。因此，採 用掩模對準器的外部對準是無法使用在該目的上。 上述的問題，藉由採用不是外部對準而是內部對準即 利用微透鏡陣列形成聚光作用的自我對準是能夠解決。例 如日本專利第3 24 3 1 6 6號及專利第3 3 09 849號公報中所揭 示的方法：是將未硬化狀態下具有黏著性但硬化狀態下不 具黏著性的材料層疊在未形成有微透鏡陣列的基板平坦面 之後，從微透鏡陣列側照射紫外線或電離幅射使只有焦點 部份是成硬化後從這上面層疊黑色膜進行壓合後藉由剝離 使黑色膜殘留在未硬化保有黏著性的區域。 然而，上述方法有以下諸問題，要維持穩定的生產實 屬困難。 首先，是有光硬化型黏著劑的特性穩定性問題。黑色 膜是附著在光硬化型黏著劑的未硬化部。該部份是爲未產 生光反應的光反應產生部份，慢慢地因該反應逐漸產生， 導致黑色膜的附著力逐漸變差。 其次，是黑色膜的機械特性問題。黑色膜所被要求的 特性是極微妙，從生產流程上的問題到製品耐久性的問題 -11 - (7) (7)1248551 都有許多問題。黑色膜於一般上是層疊在剝離式薄膜上來 使用，但留有黏著部而在非黏著部進行剝離的現象是在下 述流程產生。這是在剝離式薄膜的未附著面是壓合在局部 性硬化的光硬化型粘著層的表面上之後藉由剝離來執行， 但剝離時在界面產生的現象如下述。 首先，於黑色膜-黏著性殘留部間是不准剝離。其次 當然於黑色膜-黏著性消滅部間是必須剝離。此外，於黑 色膜一剝離式薄膜間，在感光性黏著劑層的黏著性殘留部 是必須剝離，在黏著性消滅部是不准剝離。再加上，黑色 膜於感光性黏著劑層的黏著性殘留部和黏著性消滅部的邊 界部是需爲斷裂，並且黑色膜內部的構造破壞不得產生。 即’若是利用黑色層內部的破壞來使感光性黏著劑層的黏 著性殘留部和剝離式薄膜雙方成附著時，殘留在屏幕表面 '··· 上的黑色膜厚度會變薄導致無法獲得完全的黑色度這是不 被允許的。 如此’黑色膜所被要求的特性是以感光性黏著劑層與 剝離式薄膜各特性彼此的均衡來決定的極微妙特性，所以 難以稱得上是穩定生產所適合的流程。 【發明內容】 :·. (發明欲解決之課題） 本發明是爲解決上述問題點而爲的發明，目的在於提 供一種可使習知非要以不穩定性步驟來形成獲得的遮光層 能夠以穩定性步驟來形成的具優秀實用性的實投影顯示器 -12 - (8) (8)1248551 用屛幕之微透鏡陣列片之製造方法。 (用以解決課題之手段） 接著是參照所附圖面對本發明主旨進行說明。 其是一種從光源側依順序至少配置有菲涅耳透鏡和微 透鏡陣列片1的實投影顯示器用屏幕之微透鏡陣列片之製 造方法，除了微透鏡陣列片1相關的微透鏡陣列3的焦點 及其附近區域以外’至少是依順序進行下述（1 )項步驟 、（2 )項步驟、（3 )項步驟及（4 )項步驟來形成有遮 光層2。 (1 )項步驟：其是對表面形成有微透鏡陣列3的微 透鏡陣列片1的背面塗抹對可視光而言是爲透明的光硬化 型樹脂組成物4之步驟。 (2 )項步驟：其是對形成有微透鏡陣列3的微透鏡 陣列片】的表面從該微透鏡陣列片1的主平面垂直方向照 射大致平行的光使上述微透鏡陣列3的焦點及其附近區域 的光硬化型樹脂組成物4硬化之步驟。 (3 )項步驟：其是以溶劑來去除上述光硬化型樹脂 組成物4未硬化部份之步驟。 (4 )項步驟：其是對去除上述光硬化型樹脂組成物4 未硬化部份後所形成的缺口部塗抹硬化性黑色流體之步驟 〇 此外，是關於申請專利範圍第]項所記載的實投影顯 示器用屏幕之微透鏡陣列片之製造方法中，以（4 )項步 -13- 1248551 ⑼ 驟是採用··在微透鏡陣列片〗的背面全面塗抹硬化性黑色 流體後’是利用彈性板狀體摩擦該微透鏡陣列片1的背面 ，使光硬化型樹脂組成物4的未硬化部份去除，於該去除 所形成的缺口部塗抹硬化性黑色流體之步驟爲特徵的實投 影顯示器用屏幕之微透鏡陣列片之製造方法。 另外’是關於申請專利範圍第1項所記載的實投影顯 示器用屏幕之微透鏡陣列片之製造方法中，以光硬化型樹 脂組成物4是採用：利用紫外線以光自由基反應或光陽離 子反應來進行硬化的材料爲特徵的實投影顯示器用屏幕之 微透鏡陣列片之製造方法。 此外，是關於申請專利範圍第2項所記載的實投影顯 示器用屏幕之微透鏡陣列片之製造方法中，以光硬化型樹 脂組成物4是採用：利用紫外線以光自由基反應或光陽離 子反應來進行硬化的材料爲特徵的實投影顯示器用屏幕之 微透鏡陣列片之製造方法。 另外，是關於申請專利範圍第1項至第4項任一項所 記載的實投影顯示器用屏幕之微透鏡陣列片之製造方法中 ，以光硬化型樹脂組成物4未硬化部去除用溶劑是採用極 性有機溶劑爲特徵的實投影顯示器用屏幕之微透鏡陣列片 之製造方法。 此外，是關於申請專利範圍第1項至第4項任一項所 記載的實投影顯示器用屏幕之微透鏡陣列片之製造方法中 ，以硬化性黑色流體是採用黑色顏料分散於其中的高分子 量聚合物溶解於溶劑後的塗料或者是於殘留著反應性原子 -14 - (10) (10)1248551 團的單體和低聚物之混合物中分散著黑色顏料來形成的塗 料爲特徵的實投影顯示器用屏幕之微透鏡陣列片之製造方 法。 另外，是關於申請專利範圍第5項所記載的實投影顯 示器用屏幕之微透鏡陣列片之製造方法中，以硬化性黑色 流體是採用黑色顏料分散於其中的高分子量聚合物溶解於 溶劑後的塗料或者是於殘留著反應性原子團的單體和低聚 物之混合物中分散著黑色顏料來形成的塗料爲特徵的實投 影顯示器用屏幕之微透鏡陣列片之製造方法。 (發明效果） 由於本發明是構成爲如以上所述，因此能夠提供一種 可使習知非要以不穩定性步驟來形成獲得的遮光層能夠以 穩定性步驟來形成的具優秀實用性的實投影顯示器用屏幕 之微透鏡陣列片之製造方法。 【實施方式】 (發明之最佳實施形態） 根據圖面，對適合本發明的實施形態以揭示其作用效 果來進行簡單說明。 在形成實投影顯示器用屏幕之微透鏡陣列片1時，針 對形成在微透鏡陣列片1背面的透明的光硬化型樹脂組成 物4，利用對該微透鏡陣列片1的表面成大致垂直入射的 大致平行光使微透鏡3的焦點及其附近區域成硬化後，去 -15- (11) 1248551 除該光硬化型樹脂組成物4未硬化部份，於該光硬化型樹 脂組成物4去除後所形成的缺口部設置遮光層2 ’就能夠 於微透鏡3的焦點及其附近區域以外形成有遮光層2。 因此，本發明並不像習知是在光硬化型樹脂組成物上 設有硬化性黑色流體，所以遮光層附著力不會因光反應而 使差，再加上，因不需使用剝離式薄膜，所以就不需考慮 剝離式薄膜和感光性黏著層的特性，能夠提供一種可使習 知非要以不穩定性步驟來形成獲得的遮光層能夠以穩定性 φ ' 步驟來形成的具優秀實用性的實投影顯示器用屏幕之微透 鏡陣列片之製造方法。 (實施例） 接著，是根據圖面對本發明的具體性實施例進行說明 〇 本實施例’是一種從光源側依順序至少配置有菲涅耳 透鏡和微透鏡陣列片1的實投影顯示器用屏幕之微透鏡陣 φ 列片之製造方法，其是於包括微透鏡陣列片1的微透鏡陣 列3的焦點面在內的焦點面附近區域形成有遮光層2之方 法。 微透鏡陣列片1成型用的模，雖是從標準模中以電鑄 ' 等進行轉印來製成，但標準模例如是利用亮度色標光刻法 或雷射磨蝕法就能夠製成。其也可使用鑄造模亦可使用輥 軋成型模。 在如上述所製作獲得的模和做爲微透鏡陣列片i的塑 - 16 - (12) (12)1248551 膠薄膜之間夾著樹脂材料，然後施加壓力進行成型。此時 ，是使不形成有微透鏡陣列3的平面側的面與微透鏡陣列 3的焦點面成一致（具體而言，是使包括該焦點全部在內 的面即焦點面與微透鏡陣列片的該微透鏡陣列所形成的面 爲相反的面是成爲一致地來決定基板厚度和微透鏡陣列焦 點距離的關係。） 微透鏡陣列3成型用的樹脂材料’只要於可視光是爲 透明的材料並不拘是爲熱塑性樹脂或熱硬化性樹脂，任何 樹脂均可使用。微透鏡陣列片1所使用的塑膠薄膜可使用 通用的塑膠薄膜。例如：聚對苯二甲酸乙二醇酯、聚碳酸 酯、丙烯。 其次，是對成型完成後的微透鏡陣列片1的不形成有 微透鏡陣列3的平面塗抹光硬化型樹脂組成物4〔第2圖 (A )〕。膜厚，就固體物而言，即，硬化後的厚度是以 0 . I〜1 Ο μηι爲佳。該光硬化型樹脂組成物4，可使用是將 一般性光化學反應造成硬化的現象利用在工業上的材料。 即，本實施例所使用的對可視光是爲透明的光硬化型 樹脂組成物4，是指一般使用在塗料或成型上的光硬化型 樹脂組成物4，可使用是利用紫外線以光自由基反應或光 陽離子反應來進行硬化的材料。於同時，是包括單體、低 聚物、引發劑在內。視狀況而定有時也可使用增感劑。除 了這些主要成份以外，也可添加少量的界面活性劑做爲塗 料性能改善用的均塗劑。此外，黏稠度高時也可利用溶劑 來稀釋使用。 -17 - (13) (13)1248551 以光自由基反應來進行硬化的材料，例如是具有丙烯 、甲基丙嫌、乙烯、烯丙基等之加聚合性雙鍵的化合物； 以光陽離子反應來進行硬化的材料，例如是具有環氧基的 化合物。這些是以單體和低聚物的混合物來使用。 代表性的材料，爲產生加聚合反應的雙鍵，例如是使 用具有丙燒、甲基丙烯、乙烯、烯丙基等之原子團的化合 物的單體及低聚物。或者，也可使用由光陽離子觸媒來進 行硬化的環氧化合物的聚合反應或由烯硫醇（ene_thi〇l：^t 加所形成的硬化反應。另，於含有溶劑的狀況時是因應稀 釋率來決定塗抹時的膜厚。原則上溶劑是在反應前即是在 進行光照射前先蒸發去除。 將如上述的光硬化型樹脂組成物4塗抹在微透鏡陣列 片1的微透鏡陣列3形成面的相反面之後，從微透鏡陣列 3側進行光照射〔第2圖（B )〕。從該微透鏡陣列3側 進行照射的光是可採用一般光硬化反應所使用的來自於高 壓水銀燈的光。 但是，因該光必須是平行度擴散成某一定角度的大致 平行光所以就需要利用菲涅耳透鏡等適宜的光學構件5來 進行平行校正，照射的角度必須是對主平面即是對微透鏡 陣列3的形成平面成垂直角度。照射光的強度和時間是視 所使用的光硬化型樹脂組成物4的硬化特性而定。 入射光是由微透鏡3聚光集中在焦點，然後再度進行 擴散。在焦點及其附近處光線密度會變高，在形成爲是比 硬化所需要光量的臨界點還高的部份會產生硬化反應。微 -18- (14) (14)1248551 透鏡陣列片丨的厚度因焦點面是調整成幾乎是與表面一致 所以焦點是在表面所塗抹的光硬化型樹脂組成物4當中。 因此，只有該部份會硬化。 即，從微透鏡陣列3側進行照射然後入射至各個小晶 狀體上的光是以小晶狀體的聚光作用來通過焦點面上的極 窄區域。此時因量密度的上昇會使超過硬化反應臨界點的 部份進行硬化反應。適度選擇照射強度和照射時間的話是 可使只在焦點附近區域的光硬化型樹脂組成物4進行硬化 〇 硬化反應結束後，爲了去除未反應的光硬化型樹脂組 成物4是利用未反應物溶解用的溶劑來進行洗淨〔第2圖 (c )〕。爲一般的光硬化型樹脂組成物時，只要是極性 有機溶劑是能夠有相當寬廣範圍的溶劑使用。未反應物洗 淨後’最好是進行後烘乾使硬化反應結束，以事先提高形 成在焦點及其附近區域的透明的樹脂隆起的強度。 其次，爲了於透明的樹脂隆起不存在的部份塡滿遮光 層2形成用的硬化性黑色流體，首先是對形成有該透明的 樹脂隆起的微透鏡陣列片1在不形成有微透鏡陣列3的面 全面塗抹該硬化性黑色流體。硬化性黑色流體塗抹後，爲 去除氣泡先放置若干時間，接著是施加壓力及/或剪力， 以去除多餘的硬化性黑色流體〔第2圖（D )〕。 具體而言’本實施例的硬化性黑色流體是指具流動性 的黑色塗料’其是在光硬化型樹脂組成物4進行硬化之後 塗抹’接著是施加壓力以去除多餘的塗料使以指定間隔成 -19- (15) (15)1248551 配列的光硬化型樹脂組成物4的柱露出來。然後，是使該 黑色流體凝固成爲固體。該黑色流體可使用碳黑等黑色顏 料分散於其中的高分子量聚合物類溶解於溶劑後的塗料， 也可使用碳黑等黑色顏料分散於其中的殘留著反應性原子 團的單體和低聚物之混合物類所形成的塗料。此外，也可 利用溶劑來進行稀釋。 最有效並且確實的方法，是使用具彈性的板狀體來對 其表面進行摩擦。板狀體的厚度是以上述樹脂隆起的間隙 部不接觸程度的厚度爲佳。此外，板狀體長度是以微透鏡 陣列片1寬度以上爲佳。使用滿足上述條件的板狀體來對 表面進行摩擦，可使上述透露的樹脂隆起露出硬化性黑色 流體的表面。 然後’是進行該硬化性黑色流體的硬化操作。即，硬 化性黑色流體爲光硬化型時是進行光照射，硬化性黑色流 體爲熱硬化型時是提局溫度。 另’將上述透明的光硬化型樹脂組成物的溶解性參數 形成爲要比硬化性黑色流體的溶解性參數還小是可獲得良 好的結果。即’於這樣的關係下，在是將透明的光硬化型 樹脂組成物經位置選擇性硬化而形成的樹脂隆起上即使有 該光硬化型黑色流體的被覆也會因沾濕較差成爲反彈狀態 而不容易產生覆蓋。如此般的組合，例如有：針對_般的 硬化性樹脂是使用水性塗料的光硬化型黑色流體，或光硬 化型黑色流體是使用碳黑等黑色顏料分散於其中的極性高 分子溶液塗料使具有碳氟化合物的高分子成交聯型修飾在 -20- (16) 1248551 - 透明的光硬化型樹脂組成物上等。 由於本實施例是構成爲上述，因此在形成實投影顯示 器用屏幕之微透鏡陣列片1時，針對形成在微透鏡陣列片 1背面的透明的光硬化型樹脂組成物4，利用對該微透鏡 陣列片1的表面成大致垂直入射的大致平行光使微透鏡3 的焦點及其附近區域成硬化後，去除該光硬化型樹脂組成 物4未硬化部份，於該光硬化型樹脂組成物4去除後所形 成的缺口部設置遮光層2，就能夠於微透鏡3的焦點及其 附近區域以外形成有遮光層2。 因此，本發明並不像習知是在光硬化型樹脂組成物上 設有硬化性黑色流體，所以遮光層附著力不會因光反應而 使差，再加上，因不需使用剝離式薄膜，所以就不需考慮 剝離式薄膜和感光性黏著層的特性，能夠提供一種可使習 知非要以不穩定性步驟來形成獲得的遮光層能夠以穩定性 步驟來形成的具優秀實用性的實投影顯示器用屏幕之微透 鏡陣列片之製造方法。 【圖式簡單說明】 第1圖爲表示圖像光在屏幕附近的舉動說明圖。 第2圖爲本實施例的槪略說明圖。 【主要元件符號說明】 1 :微透鏡陣列片 2 :遮光層 > 21 - (17)1248551 3 =微透鏡陣列 4 :光硬化型樹脂組成物BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a microlens array sheet for a screen for a real-life projection display, and more particularly to a microlens array sheet for a screen for a real-life projection display having improved contrast Manufacturing method. [Prior Art] In general, a real projection display device mainly consists of three types of parts: a display device that generates an image for an image; and an optical system that can project image light emitted from the display device onto a projection screen; The projection of the acceptable image light is constituted by a screen. The projection screen located closest to the observer position is composed of two types of optical members, which are generally referred to as Fresnel lenses and lenticular lenses in order from the display machine side. The function of the Fresnel lens is the parallel correction of the entire image light, and the function of the lenticular lens is to adjust the diffusion angle of the pixel light emitted by each pixel. Φ In addition, most of the screens, viewed from the lenticular lens sheet, are provided with a front panel provided with an anti-reflection film on the observer side. When the lenticular sheet is exposed to the forefront, other factors such as contact can cause the lenticular sheet to deform and distorted the image, which is undesirable, but not essential. When the image light emitted by the display machine reaches the projection screen, the optical system enlarges so that the effective display area of the projection screen has a uniform cross section, so the light beam from the display device spreads toward the observer. However, not all of the image light emitted by each element spreads in the same direction -6- (2) (2) 1248551. Since the maximum direction of the intensity of the emitted image light is different for each pixel', when using a projection screen that does not have the image light diffusion angle adjustment function, it is for the observer who looks in any direction. It is impossible to display the same display quality for the entire display screen. This is because the viewing angle-brightness distribution characteristics of each pixel are different. However, in the design concept of the data display, for example, in the case of a computer screen, it is necessary to have a function for displaying the same display quality for the entire display screen for any observer who sees the effective viewing angle range. Therefore, the intensity of each of the pixels emitted by all the pixels used for the composition of the picture needs to be diffused in the effective viewing angle to be the same intensity in any of the exit angle directions. In order to use such a diffused surface, an observer who is positioned at an outer boundary portion within the effective viewing angle range may see an imminent change in display quality by slightly moving the viewpoint, but essentially the user is the observer. So it is not a problem. In addition, there is also a design idea that the display quality is preferably gradually changed due to the position of the observer within the effective viewing angle range, which is used by most people, that is, applied to a television set. Most of the conditions are designed to be from the front side, that is, the angle of view (the angle formed by the vertical line of the screen and the line of sight of the observer) = 0 when the brightness is maximized and the angle of view is gradually inclined to gradually decrease the brightness. Most of the projection displays currently available on the market are designed for this feature. In this case as well, it is necessary to have the emitted light from all the elements in the same diffusion mode. In order to make the diffusion mode of each pixel light emitted by all the pixels on the projection screen the same mode, the optical system must be used to reach the projection from the display (3) (3) 1248551 machine using the magnification optical system at various incident angles. Correction is performed by respective pixel lights having different illuminance angle distributions on the screen. In other words, the above object can be achieved by providing an optical axis (maximum illuminance display direction) and a microlens for diffusing angle correction at respective positions corresponding to the respective pixels of the projection screen surface. However, since it is necessary to accurately position the microlens on a position corresponding to most of the elements on the screen surface for projection, an extremely precise positioning operation is required, so that a high cost is required on the device, and the manufacturing cost is low because of low productivity. Become huge. Moreover, such a microlens array is designed for a combination of a specific optical system and a display machine, so that non-universality leads to an increase in manufacturing cost. Therefore, in order to avoid the positioning operation of the pixels on the display device side and the pixels on the projection screen surface, the microlenses to be disposed on the projection screen surface are generally divided into a plurality of pixels. At this time, when the pitch of the microlenses to be placed on the projection screen surface is 1/5 or less of the pixel pitch, even if a certain degree of positional deviation occurs, the resolution which is seen by the eyes is not lowered. On the other hand, it is extremely complicated and difficult to design and manufacture the optical axes for correcting the optical axis and the diffusion angle of each pixel from the projection screen, so the method used now is After the parallel correction, the entire incident light toward the screen is converted into parallel light. The microlens array is not subjected to optical axis correction. That is, on the optical machine side of the projection screen, first, the Fresnel lens configured as the first optical member is parallel-corrected, and the parallel light emitted by the Fresnel lens -8-(4) (4) 1248551 is diffused. The angle is corrected in the microlens array. Since the image light incident on the microlens array is parallel light, diffusing the emitted light into an angular distribution (i.e., diffusion angle correction) is the most important function of the microlens array. The angular distribution is determined by the shape of the unit cell surface for constituting the microlens array. As described above, all of the screens for the projection display are constructed as described above. In most cases, the diffusion microlens array uses a cylindrical lens array having a collecting effect only in the one-axis direction, but can also be used for a fly-eye lens having a collecting effect in a direction above the two axes. In addition, it is also possible to use a spherical lens array in which microballs are juxtaposed. As described above, the microlens is generally mainly a member having an image light diffusing function, but it is required to have extremely important characteristics as it is disposed at the foremost member. That is, it is the contrast of the display quality item that is important for the display. The higher the contrast, the better the display quality. In order to increase the contrast, it is necessary to reduce the brightness at the time of non-lighting while increasing the brightness of the lighting. Therefore, it is necessary to form the surface of the screen as black, but when the black object is disposed on the path through which the image light passes, the black object absorbs the image light, causing the brightness to decrease, so that it can be disposed only in the portion where the image light does not pass. Black matter, so 'at least part of the path through which the image light passes cannot be formed in black. In this way, how to make the portion of the screen where the image light does not pass is the problem that the maximum area ratio becomes a problem in reducing the brightness at the time of non-lighting. 举 The behavior of the image light near the screen surface is as follows. First, the image light emitted by the display unit -9 - (5) (5) 1248551 is radially diffused to the mirror and then incident on the screen. At this time, the image light is first passed through the phenanthrene lens. The parallel correction function of the phenanthrene lens converts the image light into substantially parallel light. The so-called substantially parallel light, not just the light that is completely parallel, but refers to the parallel light whose parallelism has a certain degree of deviation from parallel. The reason for this is that the lens of the Fresnel lens itself does not fully have the desired function. The image light B which is parallel-corrected by the Fresnel lens A as shown in Fig. 1 is incident on the microlens array C, but this is a condensed light of each small lens (a single microlens for constituting a microlens array). The effect becomes the individual concentrating light. Therefore, incident light on the screen surface is the focus of light passing through each small lens. When the microlens array is a cylindrical lens array, the focus is formed into a line shape, and the condition of the fly's eye lens is formed as a dot arrangement. It is necessary to determine the thickness of the substrate and the focal length of the microlens array in order to make the surface opposite to the surface formed by the microlens array of the surface on which the microlens array is formed. relationship. At the above-mentioned focal plane, the image light passes only through the focus. In fact, the focus is somewhat wide due to the production accuracy, the condensing characteristics of the small lens, the aberration, etc., but it is concentrated at a point, so the ratio of the portion other than the focus in the focal plane is extremely high. . If the part can be covered with a black material, a screen with a high blackening rate can be obtained. It is necessary to have a unique trick to keep the focus portion of the focal plane completely penetrating while the other part is covered with black material. The film formed of the black material must be aligned with the small lens of the microlens array, which is the pattern to be covered, but the pitch of the small lens is 30 to 200 μηι, -10- (6) (6) 1248551 It depends on the characteristics of the small lens, but it is usually 1/5 of the small lens pitch, so it is 6~4 Ο μπι. In order to make only such a small area not adhere to the black material, only the black material is attached to other parts' is usually a photochemical reaction caused by mask exposure. However, the microlens array to be covered with the black material and the substrate on which the microlens array is formed are made of plastic, which does not have dimensional accuracy and dimensional stability capable of requiring such a high-precision positioning work flow. Therefore, external alignment using a mask aligner cannot be used for this purpose. The above problem can be solved by adopting self-alignment which is not externally aligned but internally aligned, i.e., using a microlens array to form a condensing effect. For example, the method disclosed in Japanese Patent No. 3 24 3 1 6 6 and Patent No. 3 3 09 849 is to laminate a material which has adhesiveness in an uncured state but is not adhesive in a hardened state, and is not formed in a microscopic manner. After the flat surface of the substrate of the lens array is irradiated with ultraviolet rays or ionizing radiation from the side of the microlens array, only the focus portion is hardened, and a black film is laminated thereon, and then the black film remains in the unhardened and adhered by peeling. Sexual area. However, the above method has the following problems, and it is difficult to maintain stable production. First, there is a problem of characteristic stability of a photocurable adhesive. The black film is attached to the uncured portion of the photocurable adhesive. This portion is a part of the photoreaction which does not produce a photoreaction, and gradually proceeds due to the reaction, resulting in a gradual deterioration of the adhesion of the black film. Second, it is a problem of the mechanical properties of the black film. The characteristics required for black films are extremely subtle, from problems in the production process to the durability of the product. -11 - (7) (7) 1248551 There are many problems. The black film is generally used by laminating on a release film, but the phenomenon of leaving the adhesive portion and peeling off at the non-adhesive portion is caused by the following flow. This is performed by peeling after the unattached surface of the release film is pressed against the surface of the locally cured photocurable pressure-sensitive adhesive layer, but the phenomenon occurring at the interface at the time of peeling is as follows. First, no peeling is allowed between the black film-adhesive residue. Secondly, of course, the black film-adhesive elimination part must be peeled off. Further, between the black film and the release film, the adhesive residue portion of the photosensitive adhesive layer must be peeled off, and the adhesive removal portion is not allowed to be peeled off. Further, the black film is required to be broken at the boundary portion between the adhesive residue portion and the adhesive eliminating portion of the photosensitive adhesive layer, and structural damage inside the black film is not generated. In other words, when the adhesive residue in the photosensitive adhesive layer and the peeling film are adhered by the destruction inside the black layer, the thickness of the black film remaining on the screen surface is reduced, resulting in failure to obtain completeness. The blackness of this is not allowed. The characteristics required for the 'black film' are extremely delicate characteristics determined by the balance of the characteristics of the photosensitive adhesive layer and the release film, so that it is difficult to claim a suitable flow for stable production. SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and an object of the invention is to provide a light shielding layer which can be obtained by conventionally forming an unstable step. Real-life projection display with excellent practicability formed by the stability step -12 - (8) (8) 1248551 The manufacturing method of the microlens array sheet for curtains. (Means for Solving the Problem) Next, the gist of the present invention will be described with reference to the drawings. It is a manufacturing method of a microlens array sheet of a screen for a real projection display in which at least a Fresnel lens and a microlens array sheet 1 are sequentially arranged from a light source side, except for the focus of the microlens array 3 associated with the microlens array sheet 1. The light shielding layer 2 is formed by performing the following steps (1), (2), (3), and (4) in sequence, at least in the vicinity of the vicinity. (1) Step: a step of applying a photocurable resin composition 4 which is transparent to visible light to the back surface of the microlens array sheet 1 on which the microlens array 3 is formed. (2) the step of: illuminating the surface of the microlens array sheet formed with the microlens array 3 from the principal direction of the main plane of the microlens array sheet 1 with substantially parallel light such that the focus of the microlens array 3 and The step of hardening the photocurable resin composition 4 in the vicinity. Step (3): a step of removing the uncured portion of the photocurable resin composition 4 by a solvent. (4) Step: a step of applying a hardenable black fluid to the notch portion formed by removing the unhardened portion of the photocurable resin composition 4, and further relates to the description in the scope of the patent application In the manufacturing method of the microlens array sheet for the screen for projection display, (4) step -13 - 1248551 (9) is adopted. · After applying the hardening black fluid on the back side of the microlens array sheet, 'is using the elastic plate A screen for a real-life projection display characterized by the step of rubbing the back surface of the microlens array sheet 1 to remove the uncured portion of the photo-curable resin composition 4, and applying the step of forming a hardenable black fluid to the notched portion formed by the removal A method of manufacturing a microlens array sheet. In the method of manufacturing a microlens array sheet for a screen for a real-life projection display according to the first aspect of the invention, the photocurable resin composition 4 is a photo-radical reaction or photocation reaction using ultraviolet light. A method of manufacturing a microlens array sheet for a screen for a real-life projection display featuring a hardened material. Further, in the method for producing a microlens array sheet for a screen for a real-life projection display according to the second aspect of the invention, the photocurable resin composition 4 is a photo-radical reaction or photocation reaction using ultraviolet light. A method of manufacturing a microlens array sheet for a screen for a real-life projection display featuring a hardened material. Further, in the method for producing a microlens array sheet for a screen for a real-life projection display according to any one of the first to fourth aspects of the invention, the solvent for removing the uncured portion of the photocurable resin composition 4 is A method of manufacturing a microlens array sheet for a screen for a real-life projection display featuring a polar organic solvent. Further, in the method for producing a microlens array sheet for a screen for a real-life projection display according to any one of claims 1 to 4, the curable black fluid is a high molecular weight in which a black pigment is dispersed. A coating in which a polymer is dissolved in a solvent or a coating formed by dispersing a black pigment in a mixture of a monomer and an oligomer in which a reactive atom-14 - (10) (10) 12485551 is dispersed A method of manufacturing a microlens array sheet for a display screen. Further, in the method for producing a microlens array sheet for a screen for a real-life projection display according to the fifth aspect of the invention, the curable black fluid is obtained by dissolving a high molecular weight polymer in which a black pigment is dispersed in a solvent. The coating material is a method of producing a microlens array sheet for a screen for a real-life projection display, which is characterized by a coating in which a black pigment is dispersed in a mixture of a monomer and an oligomer in which a reactive atom group is left. (Effect of the Invention) Since the present invention is configured as described above, it is possible to provide an excellent practicality that can be formed by a stabilization step in which a light-shielding layer which is conventionally formed by an unstable step can be formed in a stability step. A method of manufacturing a microlens array sheet for a screen for a projection display. [Embodiment] BEST MODE FOR CARRYING OUT THE INVENTION The embodiments suitable for the present invention will be briefly described with reference to the drawings. When the microlens array sheet 1 for forming a screen for a real projection display is formed, the transparent photocurable resin composition 4 formed on the back surface of the microlens array sheet 1 is substantially perpendicularly incident on the surface of the microlens array sheet 1. After the substantially parallel light is hardened by the focus of the microlens 3 and its vicinity, -15-(11) 1248551 is removed, except for the uncured portion of the photocurable resin composition 4, after the photocurable resin composition 4 is removed. The light-shielding layer 2' is formed in the formed notch portion, and the light-shielding layer 2 can be formed outside the focal point of the microlens 3 and the vicinity thereof. Therefore, the present invention does not provide a curable black fluid on the photocurable resin composition as in the prior art, so that the adhesion of the light shielding layer is not deteriorated by the photoreaction, and further, since the peeling film is not required Therefore, it is not necessary to consider the characteristics of the release film and the photosensitive adhesive layer, and it is possible to provide a light-shielding layer which can be formed by the unstable step, which can be formed by the stability φ 'step. A method of manufacturing a microlens array sheet for a screen for a real real-life projection display. (Embodiment) Next, a specific embodiment of the present invention will be described with reference to the drawings. The present embodiment is a real-life projection display in which at least a Fresnel lens and a microlens array sheet 1 are arranged in order from the light source side. A method of manufacturing a microlens array φ column of a screen, which is a method of forming a light shielding layer 2 in a region near a focal plane including a focal plane of the microlens array 3 of the microlens array sheet 1. The mold for molding the microlens array sheet 1 is produced by transfering from a standard mold by electroforming, etc., but the standard mold can be produced by, for example, a luminance color lithography method or a laser abrasion method. It is also possible to use a casting die or a roll forming die. A resin material was sandwiched between the mold obtained as described above and the plastic film of the micro lens array sheet i, and then pressure was applied. In this case, the plane on the plane side where the microlens array 3 is not formed is aligned with the focal plane of the microlens array 3 (specifically, the surface including the focal point, that is, the focal plane and the microlens array sheet) The surface formed by the microlens array is opposite to each other in order to determine the relationship between the substrate thickness and the focal length of the microlens array. The resin material for molding the microlens array 3 is as transparent as visible light. It is not limited to a thermoplastic resin or a thermosetting resin, and any resin can be used. The plastic film used in the microlens array sheet 1 can be a general-purpose plastic film. For example: polyethylene terephthalate, polycarbonate, propylene. Next, the photocurable resin composition 4 is applied to the plane of the microlens array sheet 1 after molding in which the microlens array 3 is not formed (Fig. 2(A)). The film thickness is preferably in the case of a solid matter, that is, the thickness after hardening is 0.1 to 1 Ο μηι. The photocurable resin composition 4 can be used as an industrial material for the phenomenon of curing by a general photochemical reaction. That is, the photocurable resin composition 4 which is transparent to visible light used in the present embodiment refers to a photocurable resin composition 4 which is generally used for coating or molding, and can be used as a photo-free radical by ultraviolet rays. A material that reacts or photo-cationically reacts to harden. At the same time, it includes monomers, oligomers, and initiators. Sensitizers may sometimes be used depending on the condition. In addition to these main components, a small amount of a surfactant can be added as a leveling agent for improving the coating performance. In addition, when the viscosity is high, it can be diluted with a solvent. -17 - (13) (13) 1248551 A material which is hardened by a photoradical reaction, for example, a compound having a polymerizable double bond such as propylene, methyl propylene, ethylene, or allyl group; The material to be hardened is, for example, a compound having an epoxy group. These are used in a mixture of monomers and oligomers. A representative material is a double bond which generates a polymerization reaction, and is, for example, a monomer or oligomer which uses a compound having an atomic group such as propane, methacryl, ethylene or allyl. Alternatively, a polymerization reaction of an epoxy compound which is hardened by a photocationic catalyst or a hardening reaction by an enethiol (ene_thi〇l: ^t addition) may be used. In addition, in the case of a solvent, it is diluted. The film thickness at the time of application is determined. In principle, the solvent is evaporated before the reaction, that is, before the light irradiation. The photocurable resin composition 4 as described above is applied to the microlens array 3 of the microlens array sheet 1. After the opposite surface of the surface is formed, light is irradiated from the side of the microlens array 3 (Fig. 2(B)). The light irradiated from the side of the microlens array 3 is a high pressure mercury lamp which can be used for a general photohardening reaction. However, since the light must be substantially parallel light that is diffused into a certain angle of parallelism, it is necessary to perform parallel correction using a suitable optical member 5 such as a Fresnel lens, and the angle of the illumination must be the main plane. The plane of formation of the microlens array 3 is at a perpendicular angle. The intensity and time of the illumination light are determined depending on the hardening characteristics of the photocurable resin composition 4 used. The concentrating light of the mirror 3 is concentrated in the focus, and then diffused again. The density of the light at the focus and its vicinity becomes high, and a hardening reaction occurs in a portion which is formed to be higher than the critical point of the amount of light required for hardening. - (14) (14) 1248551 The thickness of the lens array sheet is adjusted so that the focal plane is almost the same as the surface, so the focus is on the surface-coated photo-curable resin composition 4. Therefore, only this portion will harden. That is, the light that is irradiated from the side of the microlens array 3 and then incident on each of the small lenses passes through a very narrow region on the focal plane by the condensing action of the small lens. At this time, the increase in the amount of density causes the hardening reaction to be exceeded. The portion of the critical point is subjected to a hardening reaction. When the irradiation intensity and the irradiation time are appropriately selected, the photocurable resin composition 4 in the vicinity of the focus can be hardened and hardened, and the unreacted photocurable resin is removed. The composition 4 is washed by a solvent for dissolving an unreacted material (Fig. 2(c)). When it is a general photocurable resin composition, as long as it has polarity The solvent can be used in a wide range of solvents. After the unreacted material is washed, it is preferable to perform post-baking to complete the hardening reaction to increase the strength of the transparent resin bulge formed at the focus and its vicinity in advance. In order to form a hardenable black fluid for forming a portion of the light-shielding layer 2 which is not present in the transparent resin ridge, first, the microlens array sheet 1 on which the transparent resin is formed is formed on the surface where the microlens array 3 is not formed. The sclerosing black fluid is completely applied. After the sclerosing black fluid is applied, the bubbles are removed for a certain period of time, followed by pressure and/or shear to remove excess hardenable black fluid (Fig. 2(D)). Specifically, the curable black fluid of the present embodiment refers to a black paint having fluidity, which is applied after hardening of the photocurable resin composition 4, followed by application of pressure to remove excess paint to be formed at specified intervals. -19- (15) (15) 1248551 The column of the photocurable resin composition 4 is exposed. Then, the black fluid is solidified into a solid. The black fluid may be a coating obtained by dissolving a high molecular weight polymer in which a black pigment such as carbon black is dissolved in a solvent, or a monomer and an oligomer having residual reactive groups dispersed therein using a black pigment such as carbon black. A coating formed by the mixture. In addition, solvents can also be used for dilution. The most effective and tangible method is to use a resilient plate-like body to rub the surface. The thickness of the plate-like body is preferably such a thickness that the gap portion of the resin bulge does not contact. Further, the length of the plate-like body is preferably more than the width of the microlens array sheet 1. The surface of the curable black fluid is exposed by rubbing the surface with a plate-like body satisfying the above conditions. Then ' is the hardening operation of the hardenable black fluid. In other words, when the hardening black fluid is a photocurable type, light irradiation is performed, and when the curable black fluid is a thermosetting type, the temperature is raised. Further, the solubility parameter of the above transparent photocurable resin composition is formed to be smaller than the solubility parameter of the curable black fluid, and a good result can be obtained. In other words, even if the coating of the photocurable black fluid is formed on the resin ridge formed by the positional selective hardening of the transparent photocurable resin composition, the coating is in a rebound state due to poor wettability. It is not easy to produce coverage. In such a combination, for example, a curable resin is a photocurable black fluid using an aqueous coating material, or a photocurable black fluid is a polar polymer solution coating in which a black pigment such as carbon black is dispersed. The fluorocarbon polymer cross-linking modification is performed on a -20-(16) 1248551 - transparent photocurable resin composition. Since the present embodiment is configured as described above, when the microlens array sheet 1 for forming a screen for a real projection display is used, the transparent photocurable resin composition 4 formed on the back surface of the microlens array sheet 1 is used for the microlens. After the surface of the array sheet 1 is substantially parallel to the substantially parallel incident light, the focus of the microlens 3 and its vicinity are hardened, and the uncured portion of the photocurable resin composition 4 is removed, and the photocurable resin composition 4 is removed. When the light shielding layer 2 is provided in the notch portion formed after the removal, the light shielding layer 2 can be formed outside the focal point of the microlens 3 and the vicinity thereof. Therefore, the present invention does not provide a curable black fluid on the photocurable resin composition as in the prior art, so that the adhesion of the light shielding layer is not deteriorated by the photoreaction, and further, since the peeling film is not required Therefore, it is not necessary to consider the characteristics of the release film and the photosensitive adhesive layer, and it is possible to provide an excellent practicality that can be formed by a stability step by forming a light-shielding layer which is conventionally formed by an unstable step. A method of manufacturing a microlens array sheet for a screen for a real projection display. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a diagram showing the behavior of image light in the vicinity of the screen. Fig. 2 is a schematic explanatory view of the embodiment. [Explanation of main component symbols] 1 : Microlens array sheet 2 : Light shielding layer > 21 - (17) 1248551 3 = Microlens array 4 : Photocurable resin composition
-22--twenty two-