UV-curable fresnel lens resin composition, fresnel lens, and back projection screen

Abstract: UV-curable Fresnel lens resin compositions [1a] comprising a (meth)acrylate containing hydroxyl group and aromatic ring (A1), a urethane group-contining (meth) acrylate (A2) comprising an aromatic diol, an aromatic ring-containing monofunctional (meth)acrylate (A3), and a photopolymerization initiator (B) and [1b] comprising (A1), a mono- or di(meth)acrylate monomer (A4), and (B), further supplemented with a polyester (C1) comprising an aromatic diol and a phosphate (C2) for the formation of a Fresnel lens on a sheet or plate made of a methyl methacrylate (co) polymer; a Fresnel lens formed by UV cure of composition [1a] or [1b]; and a rear projection screen including a sheet or plate carrying said Fresnel lens. The Fresnel lens has high refractive index, antistatic properties and is satisfactory in adhesion to a sheet or plate.

Description: FIELD OF THE INVENTION The present invention relates to a UV-curable Fresnel lens resin composition, a Fresnel lens, and a rear projection screen. More particularly, the invention relates to a UV-curable Fresnel lens resin composition showing good adhesion to a sheet or plate made of a homopolymer of methyl methacrylate or a copolymer of methyl methacrylate with one or more other acrylate or methacrylate (hereinafter referred to collectively as methyl methacrylate (co)polymer); a Fresnel lens comprising a resin formed by UV cure of said composition in situ on said sheet or plate; and a rear projection screen including a sheet or plate carrying said Fresnel lens. DESCRIPTION OF THE PRIOR ART The Fresnel lens heretofore used for the fabrication of a rear projection screen is manufactured typically by casting a UV-curable resin composition between a mold and a transparent resin sheet or plate made of a methyl methacrylate (co)polymer, and exposing the resin composition to ultraviolet light, and thereby curing it. With the recent trend toward reduced thickness of projection television devices, a demand exists for resins with high refractive indices and accordingly a variety of UV-curable resin compositions have been proposed (e.g. Japanese Kokai Publications Hei-5-65318, Hei-5-155944, Hei-5-247156, and USP-5453452). However, the proposed UV-curable resin compositions are unsatisfactory in the adhesion to a sheet or plate made of a methyl methacrylate (co)polymer, and require a primer on the sheet or plate. Moreover, the lens obtainable from any of those UV-curable resin compositions has the problem of static deposition of dust particles. As compositions which can be used without the aid of a primer and yet show improved adhesion to a sheet or plate, the following compositions 1 ○ and 2 ○ were proposed. On the other hand, as compositions solving the above-mentioned problem of static deposition of dust particles, the following composition 3 ○ has been proposed. 1 ○ A composition comprising diacrylate or dimethacrylate of a low molecular hydrocarbon diol (e.g. EP-510754A1) 2 ○ A composition comprising an epoxy acrylate or methacrylate(e.g. Japanese Kokai Publication Hei-5-310871) 3 ○ A UV-curable resin composition having antistatic properties (e.g. Japanese Kokai Publications Hei-1-302201 and Hei-3-157412) However, any of these compositions 1 ○ to 3 ○ has the drawback that an attempt to insure sufficiently high adhesion to a sheet or plate results in a reduced refractive index and/or poor scratch resistance of the lens surface owing to embrittlement of the resin, so that it has been impossible to obtain a Fresnel lens meeting all the requirements of acceptable adhesion, refractive index, and scratch resistance. It is an object of the present invention to provide a UV-curable resin composition capable of providing a Fresnel lens satisfactory in all the parameters of adhesion to a sheet or plate, refractive index, and scratch resistance. It is a further object of the present invention to provide a UV-curable resin composition capable of providing a Fresnel lens further having antistatic properties. It is a still another object of the present invention to provide a Fresnel lens having all of the above-mentioned characteristics. It is a further object of the present invention to provide a rear projection screen including a Fresnel lens sheet or Fresnel lens plate carrying a Fresnel lens having all of said desirable characteristics. SUMMARY OF THE INVENTION The above objects have been accomplished by the present invention which provides the following UV-curable resin composition; Fresnel lens and rear projection screen. UV-curable resin composition A UV-curable Fresnel lens resin composition for use in the formation of a Fresnel lens on a sheet or plate made of a methyl methacrylate (co)polymer, said resin composition comprising (A1) a (meth)acrylate containing hydroxyl group and aromatic ring; (A4) a mono- or di(meth)acrylate monomer with a molecular weight of 80 to 200 and a boiling point of over 150 °C at atmospheric pressure, preferably ethylene glycol di(meth) acrylate and/or tetrahydrofurfuryl (meth)acrylate; (B) a photopolymerization initiator; (C1) a polyester having a moiety of an aromatic diol (a1) represented by the following general formula: wherein Ph represents 1,4-phenylene group, R 1 , R 2 and R 3 each represents hydrogen atom or methyl group, m and n each represents an integer of 1 to 15, and (m+n) is equal to 2 to 20; and (C2) a phosphate represented by the general formula: [R(OCH 2 CH 2 ) s O] t PO(OH) (3-t) wherein R represents alkyl group containing 5 to 16 carbon atoms, s represents an integer of 1 to 4, and t represents 1 or 2. Fresnel lens A Fresnel lens comprising a resin formed by UV cure of the composition in situ on a sheet or plate made of a methyl methacrylate (co)polymer. Rear projection screen A rear projection screen comprising a Fresnel lens sheet or Fresnel lens plate carrying the Fresnel lens as disposed on a sheet or plate made of a methyl methacrylate (co)polymer. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a sectional view showing one example of a rear projection screen. In Fig. 1, the reference numeral 1 stands for a rear projection screen, 2 for a Fresnel lens sheet or Fresnel lens plate, 3 for a lenticular lens sheet, 4 for a light absorbing layer, 5 for a Fresnel lens, and 6 for a sheet or plate made of a methyl methacrylate (co) polymer. DETAILED DESCRIPTION OF THE INVENTION The composition of the present invention is a UV-curable resin composition for use in the formation of a Fresnel lens on a sheet or plate made of a methyl methacrylate (co)polymer, namely a homopolymer of methyl methacrylate or a copolymer of methyl methacrylate with one or more other (meth)acrylates. The said composition is a UV-curable resin composition of the (meth)acrylate type which is further supplemented with a polyester (C1) and a phosphate (C2). With this composition, the resin formed by UV radiation cure is a (meth)acrylate resin. the composition has a moiety of an aromatic diol (a1). The aromatic diol (a1) is an addition product of a bisphenol with alkylene oxide as can be seen from the above general formula (1). The bisphenol mentioned above includes such species as bisphenol A, bisphenol F, and bisphenol AD. The alkylene oxide includes such species as ethylene oxide (briefly, EO), propylene oxide (briefly, PO) and these may be used in combination to give an EO-PO random addition product or an EO-PO block addition product. Each of m and n in general formula (1), both representing the number of moles of alkylene oxide added, is an integer of usually 1 to 15 and preferably 1 to 7, and (m+n) is usually 2 to 20 and preferably 2 to 12. If (m+n) is within said range, the scratch resistance of the lens available on cure of the composition will be good and the refractive index of the cured composition will be high. The addition product of the bisphenol with alkylene oxide can be produced typically by a known process such as a process that EO and/or PO are added to a bisphenol by addition reaction in the presence of a basic catalyst. The composition of the present invention comprises, as mentioned above, a (meth)acrylate containing hydroxyl group and aromatic ring (A1) a mono-or di(meth)acrylate monomer (A4), a polyester (C1), a phosphate (C2) and a photopolymerization initiator (B) as essential components. The (meth)acrylate containing hydroxyl group and aromatic ring (A1) includes but is not limited to (A11) 2-hydroxy-3-phenoxypropyl (meth)acrylate, (A12) 2-hydroxy-3-(2'-, 3'-, or 4'-methylphenoxy)propyl (meth)acrylate, (A13) (meth)acryloyloxyethyl (meth)acryloyloxy-2-hydroxypropyl phthalate, and (A14) the addition product of a bisphenol (e.g. bisphenol A, bisphenol F, or bisphenol S) glycidyl ether with a (meth)acrylate. Preferred among them are said (A11) and said (A12), both of which have low viscosity values. The phosphate (C2) of gereral formula (2) contributes to improve scratch resistance of the cured composition and, at the same time, functions as a mold release agent [R(OCH 2 CH 2 ) s O] t PO(OH) (3-t) wherein R represents alkyl group containing 5 to 16 carbon atoms, s represents an integer of 1 to 4, t represents an integer of 1 or 2. Referring to general formula (2), R is an alkyl group containing 5 to 16 carbon atoms. With R inside the above carbon number range, sufficient antistatic performance can be obtained. The symbol s stands for an integer of 1 to 4. If s is equal to zero, the phosphate (C2) will be insoluble in the composition of the invention or, even if soluble, will tend to separate out during storage. If the value of s is 5 or more, the required antistatic properties will not be fully expressed. The symbol t represents an integer of 1 or 2. If t is equal to zero, said (C2) will remain insoluble in the composition [1a] of the invention. If t is equal to 3, antistatic properties will not be fully expressed. The phosphate (C2) can be obtained by adding EO to an aliphatic alcohol of 5 to 16 carbon atoms in a known manner and reacting the addition product further with either phosphoric acid or a derivative thereof (e.g. diphosphorus pentaoxide). The aliphatic alcohol of 5 to 16 carbon atoms mentioned above is a straight-chain monohydric alcohol or a branched monohydric alcohol, which includes n-hexyl alcohol, n-octyl alcohol, 2-ethylhexyl alcohol and n-lauryl alcohol, to mention just a few preferred species. The photopolymerization initiator (B) as an essential component of the composition of the present invention includes but is not limited to benzoin alkyl ethers, benzyl dimethyl ketal, 1-hydroxycyclohexylphenylketone, 2-hydroxy-2-methyl-1-phenylpropane-1-one, benzophenone, methylbenzoyl formate, isopropylthioxanthone. These may be combindly used. The proportion of the photopolymerization initiator (B) is usually 0.1 to 10 weight % and preferably 0.5 to 6 weight %, based on the total composition weight. Where necessary, a thermal polymerization inhibitor, antifoaming agent, leveling agent, coupling agent, antistatic agent, ultraviolet absorber, and other known additives can be selectively incorporated in the composition. The composition of the present invention contains said polyester (C1) and said phosphate (C2) in addition to said components (A1) and (A4) as well as said photopolymerization initiator (B). The mono- or di(meth)acrylate monomer (A4) has a molecular weight of 80 to 200 and a boiling point of over 150 °C at atmospheric pressure. If the molecular weight is less than 80, the working environment will be adversely affected by the dermal irritancy and intense odor. On the other hand, if the molecular weight exceeds 200, adhesion of the composition to a sheet or plate made of a methyl methacrylate (co)polymer will be adversely affected. If the boiling point is equal to or below 150°C, its high volatility will interfere with the production of products of stable performance. The mono- or di(meth)acrylate monomer (A4) includes but is not limited to (A41) phenoxy ethylene glycol acrylate, (A42) tetrahydrofurfuryl (meth)acrylate, (A43) methoxyethyl (meth)acrylate, (A44) ethoxyethyl (meth)acrylate, (A45) butoxyethyl (meth)acrylate, (A46) glycidyl (meth)acrylate, (A47) 2-hydroxyethyl (meth)acrylate, (A48) diethylene glycol (meth)acrylate, (A49) 1,2- or 1,3-propylene glycol diacrylate. Preferred, among them, are (A42), (A48), and a combination thereof. In the composition [1b] of the present invention, said (meth)acrylate (A1) and said mono- or di(meth)acrylate monomer (A4) are components for improved adhesion to a sheet or plate made of a methyl methacrylate (co)polymer. The polyester (C1) mentioned above has a moiety of an aromatic diol (a1) represented by the general formula (1) and can be obtained by esterification reaction between diol compound comprising said aromatic diol (a1) and the dicarboxylic acid (a2). As the diol for a diol moiety of (C1), one or more other diols can be used in combination with (a1) where necessary. The other diols that can be used are preferably diols having molecular weights less than 400. Use of a diol with a molecular weight in excess of 400 results in a marked decrease in refractive index. Such other diol includes but is not limited to ethylene glycol, propylene glycol, neopentyl glycol, 3-methyl-1,5-pentanediol, 1,4-butanediol, 1,6-hexanediol, polyethylene glycol (degree of polymerization; 2 to 9), polypropylene glycol (degree of polymerization; 2 to 6), polycaprolactonediol (degree of polymerization; 2 or 3). The other diol or diols can be used in a proportion of usually not more than 30 weight % and preferably not more than 20 weight %, relative to (a1). The dicarboxylic acid (a2) as a constituent of said polyester (C1) includes but is not limited to maleic acid, fumaric acid succinic acid, adipic acid, phthalic acid, isophthalic acid, therephthalic acid and anhydrides thereof;, preferably, among them, are species having highly refractive indices such as maleic acid, fumaric acid, phthalic acid, isophthalic acid, terephthalic acid, acid anhydride thereof and combinations of two or more of them. The number average molecular weight of said polyester (C1) is usually 5,000 to 60,000 and preferably 7,000 to 40,000. If the number average molecular weight of (C1) is within the range of 5,000 to 60,000, the composition will not retain tackiness after UV cure and the viscosity of the composition will not be increased so much that the problem that the residual air cells in the molding will interfere with lens functions will not occur. The polyester (C1) can be produced by the known esterification reaction. The OH/COOH equivalent ratio for use in the production of (C2) is usually 1.3 to 0.7 and preferably 1.2 to 0.8. The proportions of said (A1), said (A4), and said polyester (C1) in the composition of the present invention may be 10 to 50 weight % of (A1) and preferably 15 to 30 weight %, 10 to 50 weight % of (A4) and preferably 15 to 40 weight %, and 10 to 40 weight % of (C1) and preferably 15 to 35 weight %. If the proportion of (A1) is within the range of 10 to 50 weight %, adhesion to a sheet or plate made of a methyl methacrylate (co)polymer will be adequate and the viscosity of the system will be good for workability. If the proportion of (A4) is within the range of 10 to 50 weight %, adhesion to a sheet or plate made of a methyl methacrylate (co)polymer will be adequate and the refractive index of the lens will not be decreased and the viscosity of the system will be good for workability. If the proportion of (C1) is within the range of 10 to 40 weight %, desired antistatic properties will be obtained and the viscosity will not be increased so much as to cause formation of air cells in the molding and interference with lens functions. The composition of the present invention contains said phosphate (C2) in addition to said polyester (C1) as an essential component. Each of components (C1) and (C2) has its own antistatic properties. However, with (C1) alone, it must be used in a large proportion in order to obtain an adequate degree of antistaticity and this practice would adversely affect adhesion. On the other hand, (C2) alone would not provide for a sufficient antistatic effect. Thus, the use of (C1) and (C2) in combination results in improved antistatic properties to contribute to the desired performance. Furthermore, (C2) not only contributes to improved scratch resistance of the cured composition but functions as a mold release agent. The proportion of said phosphate (C2) in the composition of the present invention is usually 0.1 to 2 weight % and preferably 0.3 to 1.5 weight %. If the proportion is within the range of 0.1 to 2 weight %, (C2) adequately contributes to antistatic properties and has adequate adhesion to the substrate. In addition to said (A1) and said (A4) as essential components, the composition of the present invention may contain one or more other (meth)acrylate monomers. The other (meth)acrylate monomer that can be used includes but is not limited to the followings. Nonylphenoxy diethylene glycol (meth)acrylate Dodecylphenoxy diethylene glycol (meth)acrylate Diethylene glycol di(meth)acrylate 1,6-Hexanediol di(meth)acrylate Neopentyl glycol di(meth)acrylate Bisphenol (e.g. bisphenol A, bisphenol F, bisphenol S) or di(meth)acrylate of the addition product of bisphenol with alkylene oxide Trimethylolpropane di- or tri(meth)acrylate Pentaerythritol tri- or tetra(meth)acrylate Dipentaerythritol tri-, tetra-, penta-, or hexa(meth) acrylate Alkylene oxide-modified trimethylolpropane tri(meth) acrylate Alkylene oxide-modified pentaerythritol tetra(meth) acrylate Alkylene oxide-modified dipentaerythritol hexa(meth) acrylate The viscosity of the composition according to the present invention is preferably 500 to 5,000 cps at the casting temperature. If the viscosity on casting is within the above range, air cells will not be entrapped in the molding and hence will not impair less functions. The refractive indices (25 °C ) of the cured resins from the composition of the present invention is usually not less than 1.54 and preferably not less than 1.55. Moreover, the surface resistivities of these cured resins are usually not more than 10 13 Ω and preferably not more than 10 12 Ω. Since the composition of the present invention can thus be tailored to yield cured resins with refractive indices not less than 1.54, sufficiently short focal lengths can be realized when they are applied to the manufacture of Fresnel lens. Moreover, because the compositions have been provided with antistatic properties, no static electricity is generated in the assembling of a lens sheet or a lens plate so that improved handling workability can be expected with no deposits of dust. The compositions of the present invention can be cured by UV irradiation. There is no particular limitation on the type of UV irradiation equipment but a high-pressure mercury lamp or a metal halide lamp can be used as a radiation source. As shown in Fig. 1, the rear projection screen 1 of the invention comprises a sheet or plate 6 made of a methyl methacrylate (co)polymer and the Fresnel lens 5 formed by the UV curing of the composition of the invention in situ on the light emergence surface of said sheet or plate 6, and a lenticular lens sheet 3 comprising lenticular lenses arranged on both incidence and emergence surfaces and having light absorbing layer 4 in the non-light-converging(non-light emerging) zones formed on the emergence surface as the projected light is converged by the lenticular lenses on the incidence surface in such a manner that the Fresnel lens 5 is juxtaposed with the lenticular lenses on the incidence surface of lenticular lens sheet 3. The Fresnel lens 5 is directly formed on the sheet or plate 6 by UV cure of said composition without interposition of an adhesive layer such as a primer layer on the sheet or plate 6. The sheet or plate thus constitued by disposing thereon the Fresnel lens of the present invention may be refered to as the Fresnel lens sheet or Fresnel lens plate in the specification. The rear projection screen 1 of the present invention comprises the Fresnel lens sheet or Fresnel lens plate 2 carrying the Fresnel lens 5 formed by curing the composition of the invention, and in addition to the use in combination with the lenticular lens sheet 3 as illustrated in Fig. 1, it can be used in combination with various other alternative screen lens sheets. The sheet or plate 6 is made of a methyl methacrylate (co)polymer, viz. a homopolymer of methyl methacrylate or a copolymer of methyl methacrylate with one or more other alkyl (meth)acrylates the carbon number of the alkyl moiety of which are usually 1 to 18. The methyl methacrylate content of said sheet or plate is usually not less than 70 weight % and preferably not less than 80 weight %. If the proportion of methyl methacrylate is within said range, adequate adhesion to the cured composition of the invention will be insured. The sheet or plate 6 made of a methyl methacrylate (co) polymer can be formed by the known molding technique such as injection molding, extrusion molding, or casting. The thickness of the sheet or plate may be ranged from 0.5 to 5 mm. Production of the Fresnel lens sheet or Fresnel lens plate can be carried out typically by a process which comprises applying the composition of the invention to a Fresnel lens mold, superimposing said sheet or plate on said composition under application of pressure to avoid entrapping of air, irradiating the assemblage with ultraviolet light to cure the composition followed by releasing from the mold. EXAMPLES The following examples illustrate the present invention in further detail and should by no means be construed as defining the scope of the invention. In the examples, all parts are by weight. Test Example 1 Using the resin compositions of Examples 1 to 5 and Comparative Examples 1 to 3, Fresnel lenses were prepared by the following test method and tested for adhesion to a sheet, mold releasability, and scratch resistance. The results are shown in Table 3. Test method Each of the UV-curable resin compositions shown in Table 2 was applied, in a thickness of 50 to 150 µ m, onto a chrome-plated Fresnel lens mold (50 cm× 50 cm) by the dispenser controlled at 35 °C, and a 2 mm-thick sheet made of a methyl methacrylate copolymer (Sumipex HT(trade name), manufactured by Sumitomo Chemical) was superimposed on the dispensed resin composition in the mold under application of pressure with care exercised to avoid air entrapment. Then, using a high-pressure mercury lamp, the UV-curable resin was cured by 1,000 mJ/cm 2 of UV light and the mold was then released to provide a Fresnel lens. The mold releasability and the performance parameters of each Fresnel lens were evaluated as follows. (1) Mold releasability: The ease of release from the mold in the production of the Fresnel lens Criteria ○ : Easy to release × : Difficult to release, with deformation ensuing (2) Air entrapment: The presence or absence of air cells in the Fresnel lens Criteria ○ : no air cells × : Air cells (3) Adhesion: The degree of adhesion of the UV-cured resin composition to the sheet The sample is crosshatched with a knife at 1 mm/pitch (10×10) and a cellophane tape was set in position and peeled off at an angle of 90 degrees. The degree of exfoliation of the cured resin from the sheet was evaluated. Criteria ○ : not exfoliated × : Exfoliated (4) Scratch resistance: Scratchability of the Fresnel lens Criteria ○ : Scratching with the finger nail leaves no mark × : Scratching with the finger nail leaves a mark. Example of Synthesis 1 An autoclave equipped with a stirrer, condensor and thermometer was charged with 558 parts of lauryl alcohol followed by addition of 264 parts of ethylene oxide at 50 °C and the reaction was conducted at 200 °C for 2 hours. To the resulting alcohol (822 parts), 137 parts of diphosphorus pentaoxide was added and the reaction was further carried out at 80 to 90°C for 2 hours to provide a phosphate (C2-1). Example of Synthesis 2 In the same autoclave as used in Example of Synthesis 4, 520 parts of octyl alcohol was reacted with 176 parts of ethylene oxide at 50 °C and, then, with 280 parts of diphosphorus pentaoxide to provide a phosphate (C2-2). Comparative Example of Synthesis 1 A four-necked flask equipped with a stirrer, condensor and thermometer was charged with 400 parts of lauric acid. After 300 parts of triethanolamine was added at room temperature, the reaction was carried out at room temperature for 2 hours to provide lauric acid triethanolamine salt (LA-1). The evaluation of antistatic properties was made by the following test method. The results are shown in Table 3. Antistatic test After conditioning to a temperature of 25 °C and a humidity of 60%, the surface resistivity of each Fresnel lens was measured with Ultra High Resistance Meter (manufactured by Advantest). Examples of Synthesis 3 and 4 Using the aromatic diol (a1) and dicarboxylic acid (a2) in accordance with the formulas (weight ratios) shown in Table 1, polyesters (C1-1) and (C1-2) were synthesized by the following method of synthesis. The"refractive index (25 °C ) of each polyester thus obtained was determined with an Abbe refractometer (manufactured by Atago). The results are shown in Table 1. Method of synthesis A four-necked flask equipped with a stirrer, condensor and thermometer was charged with the indicated amounts of (a1) and (a2) as well as 0.025 part of dibutyltin oxide and the dehydration esterification reaction was carried out at 10 mmHg and 200 °C for 8 hours to provide polyesters (C1-1) and (C1-2). Example of Synthesis 3 4 Symbol Polyester (C1-1) Polyester (C1-2) a1 Bisphenol A EO (10 mol) addition product Bisphenol F PO (4 mol) addition product Amount of a1 668 400 a2 Terephthalic acid Maleic anhydride Amount of a2 144 98 Number average mol. wt. 15,000 9,500 Refractive index (25°C) 1.570 1.563 Examples 1 to 5 According to the formulas (weight ratios) shown in Table 2, resin compositions of the invention (Examples 1 to 5) were prepared. The viscosity (35 °C) of each composition prepared was measured with a BL viscosimeter (manufactured by Tokyo Keiki). In addition, 50 µ m-thick sheets were prepared and irradiated with ultraviolet light at 1000 mJ/cm 2 to give cured sheets and the refractive index (25 °C) of each cured sheet was determined. The viscosity (35 °C ) and cured refractive index (25 °C ) values are shown in Table 3. Comparative Examples 1 to 3 According to the formulas (weight ratios) shown in Table 2, comparative resin compositions (Comparative Examples 1 to 3) were prepared. The viscosity (35 °C ) and cured refractive index (25 °C) values are shown in Table 3. Example Comparative Example 1 2 3 4 5 1 2 3 A1 Aronix M-5700 50 50 55 45 55 50 50 45 A4 Light Ester EG 20 25 15 15 20 25 Light Ester THF 15 10 20 C1 C1-1 30 25 30 20 30 C1-2 25 25 30 C2 C2-1 0.3 0.5 0.5 C2-2 0.5 1.0 LA-1 1.0 3.0 Neomer BA641 5 10 5 B Darocur 1173 2 2 2 2 2 2 2 2 In the table, each component means as folows; Light Ester EG (trade name) Ethylene glycol dimethacrylate,. manufactured by Kyoeisha Kagaku Light Ester THF (trade name) Tetrahydrofurfuryl acrylate, manufactured by Kyoeisha Kagaku Neomer BA641 (trade name) Diacrylate of Bisphenol A-EO (4 mol) addtion product, manufactured by Sanyo Chemical Industries, Ltd. Aronix M-5700 (trade name) 2-Hydroxy-3-phenoxypropyl acrylate, manufactured by Toagosei Chemical Industry CO. Ltd. Darocur 1173 (trade name) 2-Hydroxy-2-methyl-1-phenylpropan 1-one, manufactured by Ciba-Geigy The UV-curable Fresnel lens resin composition of the present invention has the following advantages. 1) Excellent adhesion to a sheet or plate made of a methyl methacrylate homopolymer or a copolymer of methyl methacrylate with one or more other (meth)acrylates. 2) Easily moldable into Fresnel lens and other optical parts. 3) Providing a cured resin with a refractive index as high as 1.54 or higher and excellent chemical resistance, toughness, heat resistance, and cold resistance. 4) The cured resin is highly antistatic. Having the above-mentioned advantages, the composition of the present invention is of great utility value as a Fresnel lens material. The rear projection screen of the present invention includes the Fresnel lens sheet or Fresnel lens plate formed by curing the above UV-curable resin composition and, therefore, has an excellent Fresnel lens with high scratch resistance. Therefore, there is no risk of damage or injury even on contact with other lens sheets during transport or assembly and it is no longer necessary to treat the surface by, for example, applying silicone oil or the like between the Fresnel lens sheet or Fresnel lens plate and the lenticular lens sheet. Furthermore, the rear projection screen of the present invention has a highly antistatic Fresnel lens surface so that no deposit of dust occurs in assembly, thus contributing to improved workability. In addition, since the refractive index of the rear projection screen is as high as at least 1.54, it is possible to manufacture Fresnel lenses of short focal length to reduce the distance between the rear projection screen and the light source, thus permitting the design and manufacture of low-profile, compact projection television devices of large screen size.

Claims: A UV-curable Fresnel lens resin composition for use in the formation of a Fresnel lens on a sheet or plate made of a methyl methacrylate (co)polymer, wherein said resin composition comprises (A1) a (meth)acrylate containing hydroxyl group and aromatic ring; (A4) a mono- or di(meth)acrylate monomer with a molecular weight of 80 to 200 and a boiling point of over 150 °C at atmospheric pressure, preferably ethylene glycol di(meth) acrylate and/or tetrahydrofurfuryl (meth)acrylate; (B) a photopolymerization initiator; (C1) a polyester having a moiety of an aromatic diol (a1) represented by the following general formula: wherein Ph represents 1,4-phenylene group, R 1 , R 2 and R 3 each represents hydrogen atom or methyl group, m and n each represents an integer of 1 to 15, and (m+n) is equal to 2 to 20; and (C2) a phosphate represented by the following general formula (2): [R(OCH 2 CH 2 ) s O] t PO(OH) (3-t) wherein R represents alkyl group containing 5 to 16 carbon atoms, s represents an integer of 1 to 4, and t represents an integer of 1 or 2. The composition according to Claim 1 which contains 10 to 50 weight % of (A1), 10 to 50 weight % of (A4), 0.1 to 10 weight % of (B), 10 to 40 weight % of (C1), and 0.1 to 2.0 weight % of (C2). A Fresnel lens comprising a resin formed by UV cure of the composition claimed in claim 1 or 2 in situ on a sheet or plate made of a methyl methacrylate (co) polymer. A rear projection screen comprising a Fresnel lens sheet or Fresnel lens plate carrying the Fresnel lens according to Claim 3 as disposed on a sheet or plate made of a methyl methacrylate (co)polymer.

Inventors: HONDA MAKOTO, OKUBO MICHIHARU, OSAWA FUTOSHI, YAMASHITA TSUTOMU, HONDA, MAKOTO, OKUBO, MICHIHARU, OSAWA, FUTOSHI, YAMASHITA, TSUTOMU, Honda, Makoto, c/o Dainippon Printing Co., Ltd., Osawa, Futoshi, c/o Dainippon Printing Co., Ltd.
Applicants: DAINIPPON PRINTING CO LTD, SANYO CHEMICAL IND LTD, DAINIPPON PRINTING CO., LTD., SANYO CHEMICAL INDUSTRIES, LTD.
Application year: 1996
Main classification: G02B1
IPC codes: G03B21, G02B3, G02B1