Patent Application
20230099636
The present invention is related to a production method for a stereoscopic-image-forming device and a stereoscopic-image-forming device where first and second light control panels (parallel light-reflective panels) each having band-like light-reflective surfaces (mirror surfaces) aligned in parallel, are overlapped each other such that the respective light-reflective surfaces of the first and second light control panels are crossed in a plan view.
As a device that forms stereoscopic images using light (scattering light) emitted from the surface of an object, e.g., there is a stereoscopic-image-forming device (an optical-image-forming device) set forth in Patent Literature 1.
The image-forming device of Patent Literature 1 includes first and second light control panels formed by aligning with a constant pitch a large number of band-like light-reflective surfaces made of metal reflective surfaces inside of two transparent flat plates. The band-like light-reflective surfaces are vertically aligned over the thickness direction of each of the transparent flat plates. The image-forming device is configured by bonding together the first and second light control panels with respective one surface sides of the first and second light control panels facing each other such that the respective light-reflective surfaces of the first and second light control panels are orthogonally crossed.
Patent Literature 1: WO 2009/131128
Patent Literature 2: WO 2015/033645
When producing the above-mentioned first and second light control panels, a large number of plate-shaped transparent synthetic resin plates or glass plates (hereinafter, referred also as to “transparent plates”) having a same constant thickness and each having a metal reflective surface formed on one surface side are laminated in a manner where the metal reflective surfaces are disposed in one side to produce a laminated body, and then the first and second light control panels are cut out from the laminated body such that cut planes become perpendicular to the metal reflective surfaces.
As a result, a large deposition furnace is necessary when working on forming the metal reflective surfaces on the transparent plates. Besides, forming the metal reflective surfaces requires to repeat over 100 times a series of operations: putting one or a small numbers of transparent plate(s) in the deposition furnace; executing deposition after deaerating the furnace to have a high vacuum state; opening to atmospheric pressure and taking the deposited transparent plate(s) out from the furnace, and it is an extremely burdensome and time-consuming work. Additionally, it is poor in workability and manufacturing efficiency because this requires forming the laminated body by laminating the metal deposited transparent plates, cutting out the first and second light control panels from the laminated body by cutting the laminated body into an extremely thin predetermined thickness, and also doing other operations such as polishing the cut planes (in both sides) of the first and second light control panels, or else.
To cope with this, a method as disclosed in Patent Literature 2 is suggested. In the method, two light control panels each including a concave-convex plate material, on one surface side of which quadrilateral-cross-section grooves are formed by parallel banks and on opposing lateral surfaces of the grooves light-reflective parts are formed, are prepared, and then the two light control panels are made to face to each other such that the respective light-reflective parts thereof are orthogonally crossed or crossed.
However, there is a problem that demolding becomes extremely difficult if the height of the banks of the concave-convex plate material is high (that is, the depth of the grooves is deep) when the concave-convex plate material is formed by injection-molding. Furthermore, forming mirror surfaces on the lateral surfaces of the parallel grooves is difficult even by using technology of Patent Literature 2, and thus, there is a problem that irregularity in the shape of the products frequently occurs.
The present invention has been made in consideration of the above circumstances, and has as its object to provide a production method for stereoscopic-image-forming device and a stereoscopic-image-forming device using the production method, which is capable of easily producing the first and second light control panels and the stereoscopic-image-forming device body formed by integrating the first and second light control panels, and of obtaining clearer stereoscopic images.
In order to achieve the above object, a production method for a stereoscopic-image-forming device according to a first aspect of the present invention is a production method where first and second light control panels each having a group of band-like light-reflective surfaces standing upright and spaced in parallel are overlapped each other such that the groups of band-like light-reflective surfaces are crossed in a plan view, and the method comprises for forming the first and second light control panels:
According to a second aspect of the present invention, in the production method for a stereoscopic-image-forming device according to the first aspect of the present invention, it is preferable that in the second step the mirror surfaces be formed by sputtering, metal deposition, metal microparticle spraying, or ion beam irradiation toward the vertical surfaces from a direction along the inclined surfaces in a manner where the inclined surfaces become in shadow. This makes it possible to prevent to the utmost the mirror surfaces from being formed on the inclined surfaces of the grooves, thereby the mirror surfaces can be selectively formed on the vertical surfaces of the grooves.
According to a third aspect of the present invention, in the production method for a stereoscopic-image-forming device according to either the first or second aspect of the present invention, it is preferable that the inclined surfaces be flat surfaces or concave surfaces recessed inward. This makes it possible to further prevent the mirror surfaces from being formed on the inclined surfaces of the grooves, thereby the mirror surfaces can be selectively formed on the vertical surfaces of the grooves.
According to a fourth aspect of the present invention, in the production method for a stereoscopic-image-forming device according to any one of the first to third aspects of the present invention, it is preferable that at corner portions of triangle-cross-sections of the grooves and at corner portions of triangle-cross-sections of the protruded strips, micro flat portions be respectively formed. This makes it possible to improve the dimensional precision of the die-molding, and prevent flaws from occurring during manufacturing processes.
According to a fifth aspect of the present invention, in the production method for a stereoscopic-image-forming device according to any one of the first to fourth aspects of the present invention, it is preferable that after performing the second step a transparent resin be filled up into the grooves, and the first and second light control panels be overlapped each other in a manner where: (i) the front sides of the first and second light control panels face to each other; (ii) the front side of the first light control panel and the back side of the second light control panel face to each other; or (iii) the back sides of the first and second light control panels face to each other, such that the groups of band-like light-reflective surfaces of the first and second light control panels are crossed each other. Here, by overlapping the first and second light control panels in a manner where the sides, on which the mirror surfaces are formed, of the first and second light control panels face to each other, the groups of band-like light-reflective surfaces (the mirror surfaces) of the first and second light control panels approach each other, which improves the condensing degree of light from an object and clearer images can be obtained.
According to a sixth aspect of the present invention, in the production method for a stereoscopic-image-forming device according to the fifth aspect of the present invention, it is preferable that with respect to a refractive index of the molded preform η1, a refractive index of the transparent resin filled up into the grooves η2 be within a range of 0.8 to 1.2 times (more preferably 0.95 to 1.05 times), or the equality η1=η2 be true.
A production method for a stereoscopic-image-forming device according to a seventh aspect of the present invention comprises:
According to a eighth aspect of the present invention, in the production method for a stereoscopic-image-forming device according to the seventh aspect of the present invention, it is preferable that in the second step the mirror surfaces be formed by sputtering, metal deposition, metal microparticle spraying, or ion beam irradiation toward the vertical surfaces from a direction along the inclined surfaces in a manner where the inclined surfaces become in shadow. This makes it possible to prevent to the utmost the mirror surfaces from being formed on the inclined surfaces of the grooves, thereby the mirror surfaces can be selectively formed on the vertical surfaces of the grooves.
According to a ninth aspect of the present invention, in the production method for a stereoscopic-image-forming device according to either the seventh or eighth aspect of the present invention, it is preferable that the inclined surfaces be flat surfaces or concave surfaces recessed inward. This makes it possible to further prevent the mirror surfaces from being formed on the inclined surfaces of the grooves, thereby the mirror surfaces can be selectively formed on the vertical surfaces of the grooves.
According to a tenth aspect of the present invention, in the production method for a stereoscopic-image-forming device according to any one of the seventh to ninth aspects of the present invention, it is preferable that an annealing treatment for removing residual stress be applied to the molded preform after being formed. This makes it possible to produce a stereoscopic-image-forming device with less deformation.
According to a eleventh aspect of the present invention, in the production method for a stereoscopic-image-forming device according to any one of the seventh to tenth aspects of the present invention, it is preferable that after performing the second step, a transparent resin be filled up into the first and second grooves and a flattening treatment to the surface of the filled transparent resin be further applied. However, the filling up of the transparent resin is not an essential requirement.
According to a twelfth aspect of the present invention, in the production method for a stereoscopic-image-forming device according to any one of the seventh to eleventh aspects of the present invention, it is preferable that at corner portions of triangle-cross-sections of the first and second grooves and at corner portions of triangle-cross-sections of the first and second protruded strips, micro flat portions be respectively formed. This makes it possible to improve the dimensional precision of the die-molding, and prevent flaws from occurring during manufacturing processes.
A stereoscopic-image-forming device according to a thirteenth aspect of the present invention comprises:
According to a fourteenth aspect of the present invention, in the stereoscopic-image-forming device according to the thirteenth aspect of the present invention, it is preferable that the inclined surfaces be flat surfaces or concave surfaces recessed inward.
According to a fifth aspect of the present invention, in the stereoscopic-image-forming device according to either the thirteenth or fourteenth aspect of the present invention, it is preferable that a refractive index of the second transparent resin be within a range of 0.8 to 1.2 times (more preferably 0.95 to 1.05 times) a refractive index of the first transparent resin, or the equality η1=η2 be true.
A production method for a stereoscopic-image-forming device and a stereoscopic-image-forming device according to the present invention use a molded preform produced by any one of press-molding, injection-molding, and roll-molding. A large number of grooves formed in parallel each have an inclined surface and a vertical surface. Each of the grooves becomes wider toward the opening, and thus, molding and demolding become easier. Therefore, a stereoscopic-image-forming device, which aspect ratio defined by (the height of the groove)/(the width of the groove) is relatively high, can be produced at a relatively low cost.
Here, a metal coating can be selectively formed on each of the vertical surfaces by sputtering, metal deposition, metal microparticle spraying, or ion beam irradiation.
Furthermore, by making the inclined surfaces be flat surfaces, or more effectively, concave surfaces recessed inward, mirror surfaces can be prevented to the utmost from being formed on the inclined surfaces of the grooves.
Subsequently, a description of a stereoscopic-image-forming device and a production method for the same according to embodiments of the present invention follows with reference to the accompanying drawings.
As shown in
As shown in
A transparent resin 17 is filled up into the grooves 15, and a filled surface 18 is parallel to a back side surface 19 of the first and second light control panels 11 (e.g. transparent plate materials 12), respectively. The first and second light control panels 11 are disposed with a front side surfaces 31 of the first and second light control panels 11 (refer to
In this embodiment, it is preferable that the transparent resin constituting the shape of the first and second light control panels 11 and the transparent resin 17 filled up into the grooves 15 be the same resin; however, they may be different kinds of transparent resins. In a case of using different kinds of transparent resins, it is preferable that their refractive indexes (η) be identical or approximate. In other words, in a case of using different transparent resins, it is preferable that a transparent resin which refractive index (η2) is identical or nearly equal to the refractive index (η1) of the transparent resin constituting the shape of the first and second light control panels 11 (transparent plate materials 12) (e.g. η2 is within a range of ±20%, that is, within a range of (0.8 to 1.2)×η1, more preferably, (0.95 to 1.05)×η1) be used as the transparent resin filled up into the grooves (It is also the case in embodiments below).
Incidentally, regarding the first and second light control panels 11 in
At each of the corner portions (bottom portions) of the triangle-cross-section grooves 15 that forms an acute angle, a micro flat portion 20 is provided, and at each of the corner portions (top portions) of the triangle-cross-section protruded strips 16 that forms an acute angle, a micro flat portion 21 is provided. The each width of the micro flat portions 20, 21 is preferably 0.02 to 0.2 times the bottom width (w) of the triangle-cross-section grooves 15 and the triangle-cross-section protruded strips 16. Incidentally, the widths of the micro flat portions 20, 21 may be identical or different. By providing the micro flat portions 20, 21, the products become resistant to flaws, and besides, the accuracy of the products increases. Note that since the widths of the micro flat portions 20, 21 are narrow, in this embodiment it is explained, with the micro flat portions 20, 21 left out of account, presuming that the cross-section of each of the grooves 15 and protruded strips 16 is a triangle (It is also the case in embodiments below).
The vertical light-reflective surfaces 13 are formed by selectively performing a mirror surface treatment (mirror-finishing treatment) to vertical surfaces 23 of a molded preform 22 made from a transparent resin (described below) (refer to
Although the inclined surfaces 14 are flat surfaces as described above, the inclined surfaces 14 of the present invention includes cases even where the cross-section is a concave surface recessed inward 24, 25, and the cross-section is a concave surface making use of a part of a polygon as shown in
The concave surface 24 shown in
The concave surface 25 shown in
Note that the concave surface is not limited to the above-mentioned shapes, but may be configured by combining a flat surface and a curved surface.
As a result, by performing sputtering or other methods to the vertical surfaces 23 along the inclined surfaces 14 with an angle equal to or beyond the cross-section inclination angle θ1 of the flat inclined surface 14 (e.g. 1 to 10 degrees) shown in
By forming the vertical light-reflective surfaces 13 as explained above, in
In other words, as shown in
In the operation of the stereoscopic-image-forming device 10, when the lights enter into the transparent plate material 12 from the air and when the lights exit from the transparent plate material 12 into the air, a refraction phenomenon or, according to the circumstances, a total reflection phenomenon of the lights may occur. Therefore, it is necessary to use the stereoscopic-image-forming device 10 while taking in consideration the possibility of occurrence of these phenomena. (It is also the case in embodiments below). Incidentally, the inclined surfaces 14 become light transmissive surfaces as they are.
In the stereoscopic-image-forming device 10, the cross-section of each of the protruded strips and grooves therebetween may be a rectangle or square shape; however, in this case, if the height-to-width ratio (height/width) is equal to or more than 1.5, the production (especially, the demolding) becomes difficult. In this embodiment, since each of the grooves 15 formed between the protruded strips 16 has a triangle-cross-section that width becomes narrower toward the bottom side, the production of the molded preform 22 by injection-molding becomes easier.
Subsequently, a production method for the stereoscopic-image-forming device 10 is explained with reference to
As shown
In this case, it is preferred that as the material of the molded preform 22, a thermoplastic resin such as polymethylmethacrylate (acrylic resin), amorphous fluororesin, PMMA, COP, optical polycarbonate, fluorine based polyester, polyether sulfone or the like be used. The dimensions of the molded preform 22 are approximately the same as the dimensions of the light control panel 11. As described above, each of the grooves 15 is tapered so as to widen outwardly; thus, demolding efficiency of the molded preform 22 is excellent and the vertical surfaces can be easily obtained even if they are long. Incidentally, the annealing treatment for removing the residual stress having occurred while molding is applied to the molded preform 22. The annealing treatment is performed by, e.g., placing the molded preform 22 in an electric furnace, a hot air dryer or a hot water bath (heated solvent) for a predetermined time length (It is also the case in embodiments below; hereinbefore: a first step).
Next, the mirror surfaces (the vertical light-reflective surfaces 13) are selectively formed only on the vertical surfaces 23 by a method shown in
As other ways to selectively form the mirror surfaces on the vertical surfaces 23, there are a way of performing the metal deposition (PVD or CVD) only to the vertical surfaces 23 after masking all the inclined surfaces 14, and a way of accelerating the metal particles using magnetic field in the metal deposition. There is also a way where, firstly, a film coating treatment that can be removed in a post-process is applied only to the inclined surfaces 14, secondly, any one of the metal deposition, sputtering, metal microparticle spraying, or ion beam irradiation is performed to the vertical surfaces 23 and the surface of the coated film, and then the coated film is removed to expose the transparent inclined surfaces 14. Incidentally, as the coating film, it can be selected from coating films that are removable (i) by chemicals (solvents), (ii) by ultraviolet irradiation from the back side, or (iii) by heating up to a temperature with which the molded preform does not deform (Hereinbefore: a second step).
Subsequently, as shown in
After that, as shown in
Next, with reference to
In the stereoscopic-image-forming device 40, triangle-cross-section grooves 42 (first grooves) each having a vertical surface 46 and an inclined surface 47 and triangle-cross-section protruded strips 44 (first protruded strips) formed by the grooves 42 next to each other are respectively arranged in parallel on one side of the transparent plate material (having a thickness h3) 41 positioned in the middle. Additionally, triangle-cross-section grooves 43 (second grooves) each having a vertical surface 48 and an inclined surface 49 and triangle-cross-section protruded strips 45 (second protruded strips) formed by the grooves 43 next to each other are respectively arranged in parallel on the other side of the transparent plate material 41. A molded preform 50 is produced by any one of press-molding, injection-molding and roll-molding such that the grooves 42 formed on one side of the transparent plate material 41 and the grooves 43 formed on the other side of the transparent plate material 41 are orthogonally crossed or crossed in a plan view with an angle of e.g. 85 to 95 degrees, preferably 88 to 92 degrees. The molded preform 50 is made from a transparent resin (first transparent resin) as same as the molded preform 22 according to the first embodiment.
At the bottom portions (corner portions) of the triangle-cross-section grooves 42, 43 and at the top portions (corner portions) of the protruded strips 44, 45, micro flat portions (not shown in Figs.) are provided as same as the above-described stereoscopic-image-forming device 10. The material, production method, and specifications (dimensions h2 and 81) of the molded preform 50 are the same as those of the stereoscopic-image-forming device 10. However, in this embodiment the thickness (h3) of the transparent plate material 41 is twice the thickness (h1) of the transparent plate material 12 (hereinbefore: a first step).
Subsequently, vertical light-reflective surfaces 51, 52 that are the mirror surfaces are selectively formed by performing the mirror surface treatment only to vertical surfaces 46 of the grooves 42 and vertical surfaces 48 of the grooves 43 respectively provided on the both sides of the transparent plate material 41, as mentioned above, by metal deposition, sputtering, or according to the circumstances, spraying metal microparticles or ion beam irradiation (an intermediate molded preform, hereinbefore: a second step). The stereoscopic-image-forming device 40 in a state of a flat plate having the first and second light control panels which exposed surfaces are flat surfaces formed on the front and back sides thereof is made by filling up the grooves 42, 43 of the intermediate molded preform with a transparent resin 53, 54 (the second transparent resin) and applying the flattening treatment to the filled surfaces (hereinbefore: a third step).
As the mirror surface treatment to form the mirror surfaces only on the vertical surfaces 46 of the grooves 42 and the vertical surfaces 48 of the grooves 43, as same as the aforementioned embodiment, there are a way of sequentially or simultaneously performing the metal deposition or the sputtering to the front and back surfaces of the molded preform 50 and other ways.
In
The present invention is not limited to the above-mentioned embodiments, and the present invention is applied also in the cases where the elements of or the production methods for the stereoscopic-image-forming device according to each of the embodiments are combined to configure or produce a stereoscopic-image-forming device. Note that in the embodiments above, the vertical light-reflective surfaces (mirror surfaces) are formed on the both sides of each of the metal coatings.
In the present invention explained above, the flattening treatment includes the cases of forming by cutting or polishing as well as pushing by presses or else and molding by dies.
The production method for a stereoscopic-image-forming device and the stereoscopic-image-forming device according to the present invention enable a stereoscopic-image-forming device which aspect ratio is relatively high to be easily and inexpensively produced. Therefore, the stereoscopic-image-forming device can be effectively utilized for appliances that require an image (e.g. medical appliances, home appliances, motor vehicles, aircrafts, vessels, or else).
10: stereoscopic-image-forming device,
11: first light control panel, second light control panel,
12: transparent plate material,
13: vertical light-reflective surface,
14: inclined surface,
15: groove,
16: protruded strip,
17: transparent resin,
18: filled surface,
19: surface,
20, 21: micro flat portion,
22: molded preform,
23: vertical surface,
24, 25: concave surface,
26, 27: flat surface,
28: metal reflective film,
29: gas flow,
30: intermediate preform,
31: surface,
40: stereoscopic-image-forming device,
41: transparent plate material,
42, 43: groove,
44, 45: protruded strip,
46: vertical surface,
47: inclined surface,
48: vertical surface,
49: inclined surface,
50: molded preform,
51, 52: vertical light-reflective surface,
53, 54: transparent resin,
55: outer frame
| Number | Date | Country | Kind |
|---|---|---|---|
| 2017-013351 | Jan 2017 | JP | national |
| PCT/JP2017/005727 | Feb 2017 | JP | national |
This application is a divisional of U.S. application No. 16/480,038 filed on Jul. 23, 2019, which is a 371 of International Application No. PCT/JP2017/012622 filed on Mar. 28, 2017, which are incorporated by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16480038 | Jul 2019 | US |
| Child | 18062180 | US |
