WikiPatents - Community Patent Review
Create Free Account  |  License or Sell Your Patent  |  WikiPatents Marketplace  |  WikiPatents Blog
Username:  Password:  
    
Advanced Search
Light shielding screen structure and a process for producing the same    

Get related patents on CD
United States Patent4877308   
Link to this pagehttp://www.wikipatents.com/4877308.html
Inventor(s)Okuno; Osamu (Chigasaki, JP); Sugiyama; Shigeru (Fuji, JP)
AbstractA light shielding screen structure comprising a first light transmissible substrate, a second light transmissible substrate and, interposed therebetween, a light shielding screen comprising a perforated structure comprising a plurality of fine partition walls and apertures defined by said partition walls, said first and second light transmissible substrates being connected respectively to both end surfaces of the parition walls of the light shielding screen through a photocured adhesive layer. The screen structure exhibits a peeling strength of 50 g/cm or more at the connection between each partition wall and each light transmissible substrate and includes a fillet of not greater than 5 .mu.m in width in each aperture at a corner portion defined by the inner wall of each aperture and the inner surface of each light transmissible substrate. The light shielding screen structure exhibits not only excellent mechanical strength but also excellent optical properties and is advantageously used in various indicators and image indicating devices.
   














 Title Information Submit all comments and votes
 
Patent Text Patent PDF Print Page Summary File History
Plain text PDF images Print Summary File History Custom Search
Inventor     Okuno; Osamu (Chigasaki, JP); Sugiyama; Shigeru (Fuji, JP)
Owner/Assignee     Asahi Kasei Kogyo Kabushiki Kaisha (Osaka, JP)
Patent assignment
All assignments
Company News
Publication Date     October 31, 1989
Application Number     07/201,467
PAIR File History     Application Data   Transaction History
Image File Wrapper   Patent Term   Fees
Litigation
Filing Date     June 2, 1988
US Classification     359/601 359/900 362/354
Int'l Classification     G02B 027/00
Examiner     Hix; L. T.
Assistant Examiner     Rutledge; D.
Attorney/Law Firm     Birch, Stewart, Kolasch & Birch
Address
Parent Case    
Priority Data     Jun 24, 1987[JP]62-155511
USPTO Field of Search     350/276 R 350/276 SL 350/320 350/321 350/322 350/117 362/29 362/30 362/255 362/256 362/351 362/353 362/354
Patent Tags     light shielding screen
   
Enter a comma (,) or semicolon (;) between multiple tag words/phrases.
Describe this patent:
 Amusing   
 Clever   
 Complex   
 Efficient   
 Historic   
 Important   
 Innovative   
 Interesting   
 Practical   
 Simple   
[no votes]
Patent WIKI

Share information and news about this patent, including information and news about the technology, inventors, company, ligation and licensing.

 References Submit all comments and votes
 
*references marked with an asterisk below are user-added references
 U.S. References
 
Add a new US reference:  
ReferenceRelevancyCommentsReferenceRelevancyComments
2053173



[0 after 0 votes]
3102460



[0 after 0 votes]
4820021
Usubuchi
359/601
Apr,1989

[0 after 0 votes]
4688156
Suzuki
362/354
Aug,1987

[0 after 0 votes]
4506953
Shimizu
359/614
Mar,1985

[0 after 0 votes]
4342821
Galves
430/12
Aug,1982

[0 after 0 votes]
 Foreign References
 Other References
 Market Review Submit all comments and votes
   
Market Size
Estimate the gross annual revenues of the relevant market sector:
> $10B
$5B - $10B
$2B - $5B
$500M - $2B
$100M - $500M
$10M - $100M
$1M - $10M
$500K - $1M
$100K - $500K
< $100K
[No votes]
$0
 
$0   $2.5B   $5B   $7.5B   $10B

[0 market size comments]
Market Share
Estimate the percentage of the relevant market sector this invention will capture:
75% - 100%
50% - 74.99%
25% - 49.99%
10 - 24.99%
5 - 9.99%
2 - 4.99%
1 - 1.99%
< 1%
[No votes]
0.0%
 
0%   25%   50%   75%   100%

[0 market share comments]
Reasonable Royalty
What percentage of gross sales should the inventor or assignee be paid?
75% - 100%
50% - 74.99%
25% - 49.99%
10 - 24.99%
5 - 9.99%
2 - 4.99%
1 - 1.99%
< 1%
[No votes]
0.0%
 
0%   25%   50%   75%   100%

[0 reasonable royalty comments]
Public's "Guesstimation" of Royalty Value
Market SizeN/A[No votes]
xMarket ShareN/A[No votes]
xReasonable RoyaltyN/A[No votes]

N/A

[0 Guesstimation of Royalty Value Comments]
License Availablity
If you are NOT the owner or assignee, answer here:
Yes, license is available for purchase

No, license is not currently available



[No votes]
[0 license availability comments]
License Availablity
If you ARE the owner or assignee, answer here:
Yes, license is available for purchase

No, license is not currently available



[No votes]
[0 owner/assignee comments]
Competitive Advantage
Does this invention have a significant competitive advantage over similar technologies?
Yes

No



[No votes]
Most helpful competitive advantage comment
[No comments]

[0 competitive advantage comments]
Commercial Alternatives
Are there viable commercial alternatives for this invention?
Yes

No



[No votes]
Most helpful commercial alternative comment
[No comments]

[0 commercial alternatives comments]
 Technical Review Submit all comments and votes
 Claims Submit all comments and votes
 


What is claimed is:

1. A light shielding screen structure comprising:

a first light transmissible substrate;

a second light transmissible substrate; and

a light shielding screen interposed between said

first light transmissible substrate and said second

light transmissible substrate,

said light shielding screen comprising a photocured resin composition layer and a plurality of apertures passing through said resin composition layer,

said apertures in said resin composition layer forming a perforated structure of a striped or sectioned pattern, in which said resin composition layer constitutes partition walls defining said apertures,

said apertures having their respective upper and lower openings respectively defined by the upper and lower ends of said partition walls,

the upper and lower end surfaces of said partition walls being connected respectively to said first light transmissible substrate and said second light transmissible substrate through a photocured adhesive layer, with part of the photocured adhesive layer which protrudes outwardly from the areas of the upper and lower end surfaces of said partition walls forming a fillet in each aperture at a corner portion which is defined by the inner wall of each aperture and the inner surface of each light transmissible substrate,

the connection between each partition wall and each light transmissible substrate having a peeling strength of 50 g/cm or more, and

said fillet having a width of not greater than 5 .mu.m.

2. A light shielding screen structure according to claim 1, wherein each partition wall contains a dye or a pigment.

3. A light shielding screen structure according to claim 1, wherein each aperture has a width of from 20 to 500 .mu.m, and each partition wall has a height of from 50 to 1,000 .mu.m, and a thickness of 5 to 500 .mu.m, the ratio of the thickness of each partition wall to the width of each aperture being from 1/1 to 1/10, the ratio of the width of each aperture to the height of each partition wall being from 1/0.5 to 1/5.

4. A light shielding screen structure according to claim 1, wherein said photocured adhesive layer comprises a photocured product of a polymer which has been three-dimensionally polymerized by ionic addition reaction and has terminal ethylenically unsaturated bonds in the molecule.

5. A light shielding screen structure according to claim 4, wherein said polymer is a product produced by polymerizing a compound having a plurality of functional groups having an active hydrogen atom, a compound having a plurality of functional groups capable of being ionically added by the action of functional groups having an active hydrogen atom, and a compound having at least one functional group capable of participating in ionic addition reaction and having a terminal ethylenically unsaturated bond.

6. A process for producing a light shielding screen structure comprising:

(a) providing a light shielding screen comprising a perforated structure comprising a plurality of partition walls and apertures defined by said partition walls, said partition walls being arranged to form the apertures in a striped or sectioned pattern, said light shielding screen being in a composite form in which said light shielding screen is connected at one end surface of each partition wall to a first light transmissible substrate through a photocured adhesive layer or being in a single form;

(b) in the case of the light shielding screen in a single form, pressing a first light transmissible substrate having a photocurable adhesive layer and a second light transmissible substrate having a photocurable adhesive layer respectively against both sides of said light shielding screen to obtain a laminate assembly, or

in the case of the light shielding screen in a composite form, pressing said light shielding screen against a second light transmissible substrate having a photocurable adhesive layer on its side of the photocurable adhesive layer to obtain a laminate assembly; and

(c) exposing the laminate assembly to active rays to cure the photocurable adhesive layer, thereby providing a connection between each partition wall and each light transmissible substrate having a peeling strength of 50 g/cm or more and providing a fillet having a width of 5 .mu.m or less, said fillet being defined as part of the photocured adhesive layer which protrudes outwardly from the areas of the upper and lower end surfaces of said partition walls in each aperture at a corner portion defined by the inner wall of each aperture and the inner surface of each light transmissible substrate.

7. A process for producing a light shielding screen structure according to claim 6, wherein said photocurable resin composition contains a dye or a pigment, or said photocurable resin composition contains no pigment or dye and said partition walls are dyed subsequent to step (c).

8. A process for producing a light shielding screen structure according to claim 6, wherein each aperture has a width of from 20 to 500 .mu.m, and each partition wall has a height of from 50 to 1,000 .mu.m, and a thickness of 5 to 500 .mu.m, the ratio of the thickness of each partition wall to the width of each aperture being from 1/1 to 1/10, the ratio of the width of each aperture to the height of each partition wall being from 1/0.5 to 1/5.

9. A process for producing a light shielding screen structure according to claim 6, wherein said photocurable adhesive layer comprises a polymer which has been three-dimensionally polymerized by ionic addition reaction and has terminal ethylenically unsaturated bonds in the molecule.

10. A process for producing a light shielding screen structure according to claim 8, wherein said polymer is a product produced by polymerizing a compound having a plurality of functional groups having a active hydrogen atom, a compound having a plurality of functional groups capable of being ionically added by the action of functional groups having an active hydrogen atom, and a compound having at least one functional group capable of participating in ionic addition reaction and having a terminal ethylenically unsaturated bond.
 Description Submit all comments and votes
 


BACKGROUND OF THE INVENTION

1. Field Of The Invention

The present invention relates to a light shielding screen structure. More particularly the present invention is concerned with a light shielding screen structure having not only a high mechanical strength but also excellent optical properties, which is useful for adjusting the angles of the light rays emitted from various indicators such as indicators for instruments mounted on an instrument panel of an automobile and from image-indicating devices such as the CRT (cathode-ray tube) of a television receiver and for shielding extraneous light rays incident on the indicators or image-indicating devices, thereby preventing the deterioration of an image projected.

2. Discussion Of Related Art

Various light shielding screens have heretofore been proposed. For example, Japanese Patent Application Publication No. 55-7562/1980 and U.S. Pat. No. 2,053,173 disclose a light shielding screen which is produced by a process which comprises putting transparent plastic layers and light shielding plastic layers one upon another to form a block consisting of laminated layers and slicing the resulting block perpendicularly relative to the laminated layers.

However, in the above-mentioned conventional light shielding screen, it is difficult to precisely control the width and the thickness of the transparent layer and the light shielding layer, since in slicing the block to form a light shielding screen the transparent layer and the light shielding layer undergo deformation. Further, the process necessarily involves the step of smoothing the surface exposed by slicing. Therefore, such a light shielding screen cannot be stably produced.

On the other hand, a light shielding screen having a fine structure produced from a photocurable resin composition has been proposed in Japanese Patent Application Laid-Open Specification No. 55-139250/1980. However, in the light shielding screen disclosed in the above-mentioned patent application laid-open specification, the fine partition walls are exposed. Therefore, the light shielding screen has disadvantages in that when it is actually used for various applications, there is the disadvantage that the exposed fine structure suffers physical damage upon contact with other objects, and that foreign matter such as dust etc. may accumulate in the spaces between the partition walls, thereby decreasing the light transmission.

In order to obviate the above-mentioned disadvantages, Japanese Patent Application Laid-Open Specification Nos. 57-89701, 57-165802, 58-215880 and 60-125880 and U.S. Pat. No. 4,688,156 have proposed to fill the spaces between the partition walls with a transparent resin or attach a transparent sheet to the ends of the partition walls by means of an adhesive or a double-coated adhesive tape so as to cover up the fine partition wall structure. However, in the case where the spaces are filled with a transparent resin, it is difficult to fill up the spaces between the partition walls with the transparent resin without causing bubbles to form therein. On the other hand, in the case of attaching a transparent sheet by means of an adhesive or a double-coated adhesive tape, if the amount of the adhesive used is not enough, the bonding strength between the transparent sheet and the ends of the partition walls is too low, whereas if the amount of the adhesive is in excess, the adhesive is likely to enter the spaces between the partition walls to such a degree that transmitted light rays are scattered, resulting in a decrease in light transmission. Thus, heretofore there has not been realized a light shielding screen structure satisfying both the requirements of satisfactory bond strength and excellent optical properties.

Japanese Utility Patent Application Laid-Open Specification No. 62-9201 discloses a light shielding screen structure comprising a first light transmissible substrate having a light shielding layer thereon, and a second light transmissible substrate connected to the first light transmissible substrate through the light shielding layer. The light shielding layer comprises at least one light shielding screen portion and a light non-transmissible retaining portion which includes the entire outermost peripheral area of the light shielding layer. The second light transmissible substrate is attached to the light shielding layer at only its light non-transmissible retaining portion by means of a double-coated adhesive tape. However, in preparing this light shielding screen structure, since it is necessary to provide an adhesive tape having a shape corresponding to the shape of the light shielding screen portion, the types of light shielding screen structures which may be used are limited. Further, this type of light shielding screen structure is also disadvantageous in that since there is no bonding between the light shielding screen portion of the light shielding layer and the second light transmissible substrate, when it is intended to produce a light shielding screen structure in which the light shielding screen portion has a large area relative to the light non-transmissible retaining portion, the bonding strength between the light shielding layer and the second light transmissible substrate becomes too weak, and there cannot be obtained a light shielding screen structure having a sufficient mechanical strength as a whole.

SUMMARY OF THE INVENTION

The present inventors have made extensive and intensive studies with a view toward eliminating the above-mentioned drawbacks of the conventional light shielding screen structures. As a result, they have found that when in a light shielding screen structure comprising first and second light transmissible substrates and a light shielding screen composed of partition walls and interposed between the first and second substrates, the upper and lower end surfaces of the partition walls are bonded respectively to the first and second substrates by means of a photo curable adhesive, the light shielding screen structure is advantageous in that it not only has a high mechanical strength but also has excellent optical properties. Based on these findings, the present invention has been completed.

According to the present invention, there is provided a light shielding screen structure comprising:

a first light transmissible substrate;

a second light transmissible substrate; and

a light shielding screen interposed between

said first light transmissible substrate and

said second light transmissible substrate,

said light shielding screen comprising a photocured resin composition layer and a plurality of apertures passing through said resin composition layer,

said apertures in said resin composition layer forming a perforated structure of a striped or sectioned pattern, in which said resin composition layer constitutes partition walls defining said apertures,

said apertures having their respective upper and lower openings respectively defined by the upper and lower ends of said partition walls,

the upper and lower end surfaces of said partition walls being connected respectively to said first light transmissible substrate and said second light transmissible substrate through a photocured adhesive layer, with part of the photocured adhesive layer which protrudes outwardly from the areas of the upper and lower end surfaces of said partition walls forming a fillet in each aperture at a corner portion which is defined by the inner wall of each aperture and the inner surface of each light transmissible substrate,

the connection between each partition wall and each light transmissible substrate having a peeling strength of 50 g/cm or more, and

said fillet having a width of not greater than 5 .mu.m.

Accordingly, it is an object of the present invention to provide a light shielding screen structure which not only has excellent optical properties but also excellent mechanical strength.

It is another object of the present invention to provide a light shielding screen structure of the above kind, which is simple in structure.

It is a further object of the present invention to provide a method for producing a light shielding screen structure of the character described above, which can be easily conducted through photocuring a photocurable adhesive.

The foregoing and other objects, features and advantages of the present invention will be apparent to those skilled in the art from the following description and appended claims in connection with the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

In the drawings:

FIG. 1 shows a schematic side view of one form of a light shielding screen structure according to the present invention;

FIG. 2 shows a schematic perspective view of one form of a light shielding screen to be used in the present invention;

FIG. 3 is a partly cut-away enlarged view of FIG. 1;

FIG. 4 is a partly cut-away enlarged view of FIG. 3, showing the structure of a fillet formed at the corner portion defined by the inner wall of each aperture of the light shielding screen and the inner surface of each light transmissible substrate;

FIGS. 5(a) to 5(g) are schematic views explaining one mode of a process for producing a light shielding screen structure according to the present invention, in which process a light shielding screen is provided in a composite form in which the light shielding screen is attached to a light transmissible substrate by means of a photocured adhesive; an

FIGS. 6(a) and 6(b) are schematic views explaining another mode of a process for preparing a light shielding screen structure according to the present invention, in which process a light shielding screen is provided in a single form.

In FIGS. 1 through 6(b), like parts or portions are designated by like numerals or characters.

Referring now to FIGS. 1 to 3, numeral 2a designates a first light transmissible substrate, numeral 7a an adhesive layer, numeral 1 a light shielding screen, numeral 7b an adhesive layer and numeral 2b a second light transmissible substrate. Light shielding screen 1 comprises a photocured resin composition layer and a plurality of apertures passing through the photocured resin composition layer in a direction perpendicular to the layer surface of the resin composition layer. The photocured resin composition layer cooperates with the apertures to form a perforated structure of a predetermined pattern, in which the photocured resin composition layer constitutes partition walls defining the apertures. As shown in FIG. 2, in one embodiment of the present invention, a plurality of partition walls 1A are arranged in a regular square network pattern. The apertures have their respective upper and lower openings respectively defined by the upper and lower ends of partition walls 1A. As shown in FIG. 1, the upper and lower end surfaces of partition walls 1A are connected respectively to first light transmissible substrate 2a and second light transmissible substrate 2b through photocured adhesive layer 7a, 7b.

In FIG. 4, there is shown an enlarged view illustrating how a fillet is formed. As is seen from FIG. 4, part of photocured adhesive layer 7a, 7b protrudes outwardly from the areas of the upper and lower end surfaces of the partition walls 1A to form fillet 8 in each aperture at its corner portion defined by the inner wall of each aperture and the inner surface of each light transmissible substrate 2a, 2b. The width of fillet 8 is herein defined by the length of W as depicted in FIG. 4.

In the light shielding screen structure of the present invention, due to the connection of light transmissible substrate 2a, 2b to the end surface of partition wall 1A through photocured adhesive layer 7a, 7b, protrusion of the adhesive layer into each aperture defined by the partition walls is suppressed and, accordingly, the size of fillet 8 can be minimized, while maintaining the bonding strength between light transmissible substrate 2a, 2b and partition wall 1A at a practical level. As a result, in the present light shielding screen structure, the viewable angle and haze can be controlled. Further, the light shielding screen structure of the present invention does not suffer from peeling, not only when it is subjected to blanking or cutting but also when it is fixed on an indicator, an image-indicating device and the like. In addition, because a photocurable adhesive is used, the time for completion of bonding in the process for the production of a light shielding screen structure is shortened.

As described above, light shielding screen 1 to be used in the present invention comprises a plurality of partition walls 1A made of a photocured resin composition and apertures defined thereby. Such a light shielding screen is prepared by a process comprising superimposing a negative mask having a predetermined pattern on a photocurable resin composition layer, irradiating the resin composition with active rays through the mask so as to photocure the photocurable resin so that it corresponds with the pattern, and removing the uncured resin with a developer. The height of the partition wall is equal to the thickness of light shielding screen 1, which thickness depends on the thickness of the photocurable resin composition layer

The light shielding screen to be used in the present invention has a striped pattern or a sectioned pattern. Examples of sectioned patterns include various patterns such as a circle network pattern, an ellipse network pattern, a triangle network pattern, a regular square network pattern, a rectangle network pattern, a rhombic network pattern, a parallelogram network pattern and honeycomb pattern, etc. The partition wall structure may constitute the entire part of the light shielding screen or may be locally present in the light shielding screen. In the case of the latter, the partition wall structure portion may represent a design such as a circle, a polygon, a silhouette, etc., and the remaining portion of the light shielding screen layer may constitute a light non-transmissible portion having the same thickness as that of the partition wall structure portion.

The width of an aperture defined by the partition walls may vary depending on the shape of the aperture. However, in general, if the width of the aperture is too small, the formation of partition walls becomes difficult while if the width is too large, the angle of transmitted light becomes too large, which is undesirable from a practical viewpoint. Thus, the width of the aperture is preferably in the range of from 20 to 500 .mu.m. (The term "width of an aperture" as used herein is intended to mean: the inner distance between the adjacent stripes in the case of a striped pattern; the inner diameter in the case of a circular aperture; the length of the inner minor axis in the case of an oval aperture; in the case of a polygonal aperture having sides in odd numbers, the minimum inner distance between the vertexes and the sides opposite to the vertexes; and in the case of a polygonal aperture having sides in even numbers, the minimum inner distance between the opposite sides.) Likewise, if the height of the partition wall is too large, the formation of partition walls becomes difficult while if it is too small, the angle of transmitted light becomes too large. Therefore, the height of the partition wall is preferably in the range of from 50 to 1,000 .mu.m. With respect to the thickness of the partition wall, if it is too small, the formation of the partition walls becomes difficult while if it is too large, the light transmission is lowered. The thickness is preferably in the range of from 5 to 500 .mu.m, more preferably in the range of from 10 to 200 .mu.m. In addition, if the ratio of the thickness of the partition wall to the width of the aperture is too large, the angle of the transmitted light becomes too large, while if it is too small, the formation of the partition walls becomes difficult. The ratio of the thickness of the partition wall to the width of the aperture is preferably in the range of from 1/1 to 1/10. On the other hand, if the ratio of the width of the aperture to the height of the partition wall is too large, the angle of transmitted light becomes too large, while if it is too small, the formation of the partition walls becomes difficult. The ratio of the width of the aperture to the height of the partition wall is preferably in the range of from 1/0.5 to 1/5.

The size of the light shielding screen structure of the present invention may vary depending on the applications, but in general, it is not smaller than a 5 mm.times.5 mm size. If desired, a light shielding screen structure having a great size may first be obtained, and light shielding screen structures of smaller sizes may be cut out therefrom.

In the method for producing a light shielding screen structure of the present invention, the preparation of a light shielding screen is involved. As described later, a light shielding screen may be provided in a composite form for the subsequent steps, in which composite form the light shielding screen is attached to a light transmissible substrate, or it may be prepared in a single form for the subsequent steps.

For preparing a light shielding screen in a composite form as mentioned above, there is used a method comprising: applying a photocurable resin composition in a predetermined thickness to the surface of a light transmissible substrate or laminating a sheet of a photocurable resin composition on the surface of a light transmissible substrate to obtain an assembly, the light transmissible substrate having previously been coated with a photocurable adhesive which is capable of bonding the light transmissible substrate to the photo curable resin composition when photocured; placing a negative having a predetermined pattern on the assembly; exposing the resultant assembly to active rays from a source such as an arc lamp, a mercury vapor lamp, a xenon lamp, an ultraviolet ray fluorescent lamp or the sun to cure the photocurable resin composition in accordance with the pattern of the negative and simultaneously cure the photocurable adhesive; removing the negative; and removing the non-exposed portion of the photocured resin by means of a developer to effect development, so that the desired reliefs are obtained. The above-mentioned photocurable adhesive may preferably comprise, for example, a polymer disclosed in Japanese Patent Application Laid-Open Specification No. 58-174945/1983, which has been three-dimensionally polymerized by an ionic addition reaction and has terminal ethylenically unsaturated bonds in the molecule.

In the photocuring process of the resin composition, it is preferred that the surface portions of both the ends of the resultant relief (i.e., the end surfaces of the partition walls) still contain a photocurable resin composition remaining less cured. In this connection, the following should be noted. As described later when referring to FIGS. 5(a) to 5(g), in preparing a light shielding screen, areas on the surface of the photocurable resin composition layer which correspond to the end surfaces of the partition walls are in contact with a release film when pattern forming exposure is conducted. Since such a release film generally has oxygen permeability, the areas corresponding to the end surfaces of the partition walls are caused to be contacted with oxygen. In the presence of oxygen, the radicals produced by the exposure are likely to undergo termination of the reaction and thus the photocuring reaction no longer proceeds at the end surfaces of the partition wall, whereas the inner portions of the partition walls are completely photocured. From a viewpoint of oxygen permeability, it is preferred that the release film to be interposed between the negative film and the photocurable resin composition layer (see FIGS. 5(a) to 5(g)) is made of polypropylene, cellulose ester, polycarbonate, polymethyl methacrylate, polyethylene, polystyrene, polyethylene terephthalate or the like and that the thickness of the release film is 3 .mu.m to 50 .mu.m.

In order for the photocurable resin composition to surely remain less cured at portions corresponding to the end surfaces of the partition walls, a post-exposure operation is preferably omitted or conducted with active rays as weak as 500 mJ/cm.sup.2 or less, which post-exposure operation is usually conducted in preparing a conventional light shielding screen after the pattern forming exposure and subsequent development in order to increase the strength of the partition walls. Alternatively, there may be employed a photocurable resin composition having photocuring properties lowered by incorporating a dye or a pigment. There may also preferably be employed a photocurable resin composition which contains a prepolymer having unsaturated bonds in the main chain. In these ways, less photocuring of the photocurable resin composition at portions corresponding to the upper and lower end surfaces of the partition walls can be attained.

For preparing a light shielding screen having partition walls with improved light shielding properties, a light shielding screen is dyed or it is prepared using a photocurable resin composition having incorporated therein a dye or a pigment. In the latter case, it is necessary that a dye or a pigment be incorporated in such an amount that the photosensitivity of the photocurable resin composition is not remarkably decreased. The amount of a dye or a pigment to be added is from 0.05 to 2.0 wt%, preferably from 0.1 to 1.0 wt%. Examples of dyes to be used in the present invention include cationic dyes, disperse dyes, reactive dyes, acid dyes, direct dyes and metallized dyes. Particularly, a disperse dye or a metallized dye is preferable from the viewpoint of weathering-resistant properties. The type of dye to be used may be chosen from the viewpoints of the compatibility of the dye with the photocurable resin composition and the absorption characteristics of the dye. With respect to the pigment to be used in the present invention, either an inorganic pigment or an organic pigment can be employed, and it is preferable to employ a pigment having good dispersibility.

In FIG. 5(a) to 5(g), there is schematically illustrated one mode of a process for producing the light shielding screen structure of the present invention, in which a light shielding screen is first prepared in composite form as in Example 1 which is described later.

As shown in FIG. 5(a), on transparent glass plate 3 are superimposed image-bearing negative 4, release film 5a which is made of a polypropylene film, and photocurable resin composition layer 6 in this order to obtain a photocurable resin assembly. As shown in FIG. 5(b), a separately-prepared laminate of light transmissible substrate 2a made of polyethylene terephthalate, photocurable adhesive layer 7a and release film 5b made of a polypropylene film is provided. Release film 5b is peeled off from the laminate. The laminate with release film 5b peeled off therefrom is placed on the photocurable resin assembly so that adhesive layer 7a and photocurable resin composition layer 6 are contacted with each other [see FIG. 5(c)]. Then, the resultant assembly is exposed from the side of transparent glass plate 3 to active rays to effect photocuring of not only photocurable resin composition layer 6 but also photocurable adhesive layer 7a. In this instance, as described before, it is preferred that the photocuring is conducted in such a manner that the photocurable resin composition remains less cured at portions corresponding to the end surfaces of the ultimate partition walls. Then, release film 5a is peeled off and the non-exposed (non-photocured) areas of resin layer 6A are removed for the development of partition walls, followed by dying the partition walls, thereby obtaining light shielding screen 1 in a composite form in which partition walls are connected at their respective ends to light transmissible substrate 2a through photocured adhesive layer 7a [see FIG. 5(d) and 5(e)]. Thereafter, release film 5c is peeled off from a laminate of photocurable adhesive 7b and light transmissible substrate 2b. On the laminate with release film 5c peeled off therefrom is placed the above-prepared light shielding screen 1 with light transmissible substrate 2a connected thereto in such a manner that adhesive layer 7b is contacted with the end surfaces of the partition walls of light shielding screen 1 [see FIG. 5(f) and 5(g)], and both of them are pressed to each other. Finally, the resultant laminate assembly is exposed from the side of light transmissible substrate 2b to active rays to bond the end surfaces of the partition walls to light transmissible substrate 2b by means of photocured adhesive 7b, thereby obtaining a light shielding screen structure of the present invention.

In the above process, the photocuring of photocurable adhesive layer 7a for connecting the upper ends of partition walls to upper light transmissible substrate 2a is effected simultaneously with formation of partition walls by the pattern-wise photo curing of the photocurable resin composition layer 6. Therefore, there is no danger that photocured adhesive 7a protrudes into the apertures between the partition walls of light shielding screen 1.

In the above process, it should further be noted that the the photocurable resin composition remains less cured at portions corresponding to the end surfaces of the ultimate partition walls due to the polymerization inhibiting effect of oxgen as described above. As photocurable adhesive 7a and 7b, there is preferably employed such a polymer as is disclosed in Japanese Patent Application Laid-open Specification No. 58-174945, which polymer has been three-dimensionally polymerized by ionic addition reaction and has terminal ethylenically unsaturated bonds in the molecule. When exposed to active rays, the photocurable resin composition remaining less cured in the end surfaces of the partition walls and the lower adhesive layer 7b are caused to be chemically bonded together. Therefore, although photocurable adhesive layer 7b is solid and very thin, strong bonding with the end surfaces of the partition walls can be obtained. The decreased thickness of the adhesive layer and the solid state of the adhesive layer contributes to preventing the adhesive from protrusion into the apertures so that the size of a fillet is reduced, while attaining strong bonding between the end surfaces of the partition walls and lower light transmissible substrate 2b through the photocured adhesive layer 7b.

In another mode in which a light shielding screen is produced in a single form, substantially the same procedure is conducted as in the production of a light shielding screen in a composite form, except that a photocurable adhesive is not applied to the light transmissible substrate and the transparent substrate is removed after the pattern forming exposure, as described in Japanese Patent Application Laid-Open Specification No. 60-195849/1985.

In this mode, after the photocurable resin composition layer has been subjected to pattern forming exposure, the non-exposed areas of the photocured resin composition layer are removed, thereby obtaining a light shielding screen in a single form in which the photocurable resin composition remains less cured on both the upper and lower end portions of the partition walls. Since a photocured resin composition is not bonded to the light transmissible substrate by means of a photocured adhesive, as different from the previously-mentioned mode, removal of the non-exposed areas can be easily performed as compared to the case of a photocured resin composition layer having a light transmissible substrate bonded thereto. Therefore, this mode of a process in which a light shielding screen is produced in a single form, is suitable for the production of a light shielding screen structure of the type in which partition walls having large heights are desired.

Referring to FIG. 6(a), numeral 1 designates a light shielding screen produced in a single form as mentioned above. Light shielding screen 1 is interposed between light transmissible substrate 2a coated with photocurable adhesive 7a and light transmissible substrate 2b coated with photocurable adhesive 7b as depicted in FIG. 6(a). The resultant laminate assembly is exposed from the sides of light transmissible substrates 2a and 2b to active rays. By exposure to active rays, transmissible substrates 2a and 2b are firmly bonded to light shielding screen 1 at the end surfaces of the partition walls through photocured adhesive layers 7a and 7b, respectively. Thus, a light shielding screen structure of the present invention in which the formation of a fillet, constituted of the adhesive, is restrained while attaining strong bonding between the light transmissible substrates and the light shielding screen, is obtained.

Accordingly, in another aspect of the present invention, there is provided a process for producing a light shielding screen structure comprising:

(a) providing a light shielding screen comprising a perforated structure comprising a plurality of partition walls and apertures defined by said partition walls, said partition walls being arranged to form the apertures in a striped or sectioned pattern, said light shielding screen being in a composite form in which said light shielding screen is connected at one end surface of each partition wall to a first light transmissible substrate through a photocured adhesive layer or being in a single form;

(b) in the case of the light shielding screen in a single form, pressing a first light transmissible substrate having a photocurable adhesive layer and a second light transmissible substrate having a photocurable adhesive layer respectively against both sides of said light shielding screen to obtain a laminate assembly, or

in the case of the light shielding screen in a composite form, pressing said light shielding screen against a second light transmissible substrate having a photocurable adhesive layer on its side of the photocurable adhesive layer to obtain a laminate assembly; and

(c) exposing the laminate assembly to active rays to cure the photocurable adhesive layer, thereby enabling the connection between each partition wall and each light transmissible substrate to have a peeling strength of 50 g/cm or more and providing a fillet having a width of 5 .mu.m or less, said fillet being defined as part of the photocured adhesive layer which protrudes outwardly from the areas of the upper and lower end surfaces of said partition walls in each aperture at a corner portion defined by the inner wall of each aperture and the inner surface of each light transmissible substrate.

A preferred example of a photocurable resin composition to be used in the present invention is a composition comprising a prepolymer having polymerizable ethylenically unsaturated groups, and, if desired, an ethylenically unsaturated monomer, a photosensitizer and a thermal polymerization inhibitor. Examples of prepolymers include unsaturated polyesters, unsaturated polyurethanes, oligomers of an ester-acrylate type, unsaturated polyamides, unsaturated polyimides, unsaturated polyethers and unsaturated poly(meth)acrylates, various modified products thereof such as alkyd resins and various rubber compounds having carbon-carbon double bonds. Prepolymers having a number average molecular weight of about 500 or more, usually about 500 to about 100,000 as measured by osmometry, are generally employed.

Representative examples of unsaturated polyesters and modified unsaturated polyesters include polyesters prepared by reacting unsaturated dibasic acids such as maleic acid, fumaric acid and itaconic acid or anhydrides thereof with polyvalent alcohols such as ethylene glycol, propylene glycol, diethylene glycol, triethylene glycol, glycerin, trimethylol propane, pentaerythritol, 1,4-polybutadiene having a terminal hydroxyl group, hydrogenated or non-hydrogenated 1,2-polybutadiene, butadienestyrene copolymer and butadiene-acrylonitrile copolymer; polyesters obtained by substituting a portion of the acid components of the abovementioned unsaturated polyesters with saturated polybasic acids such as succinic acid, adipic acid, phthalic acid, isophthalic acid, phthalic anhydride and trimellitic acid; and alkyd resins obtained by modifying the above-mentioned polyesters with a drying oil fatty acid or semidrying oil fatty acid.

Examples of unsaturated polyurethanes include unsaturated polyurethanes having addition-polymerizable unsaturated groups introduced by utilizing terminal isocyanate and/or hydroxyl groups of polyurethanes derived from at least one polyol having two or more terminal hydroxyl groups and at least one polyisocyanate, for example, unsaturated polyurethanes which are prepared from (i) a polyurethane having terminal isocyanate and/or hydroxyl groups and prepared from at least one polyol such as a polyhydric alcohol as mentioned above, polyester polyol or polyether polyol and at least one polyisocyanate such as tolylene diisocyanate, diphenylmethane-4,4'-diisocyanate or hexamethylene diisocyanate and (ii) at least one unsaturated mono- or dicarboxylic acid as mentioned above or its ester or polyester having active hydrogen atoms derived from hydroxyl (reactive with the terminal isocyanate) and/or carboxyl (reactive with both of the terminal isocyanate and the terminal hydroxyl) and/o