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Toppan Plans New Screen Production

01.07.2003

Toppan Printing Co. (Tokyo, Japan) (www.toppan.co.jp) is optimistic about the microdisplay-based rear-projection TV (MD-RPTV) segment. It has developed a very fine-pitch screen for use with these systems that has gained wide acceptance. As a result, it is currently building out a new screen manufacturing facility in a renovated printing plant in New Jersey.

The new facility is scheduled to be operational in 2003 and will be used to supply local manufactures of MD-RPTVs. The new screen, dubbed FC-Screen by the company's development lab in Saitama, Japan, offers high contrast and variable gain, which is desired for HDTV applications. It features an industry-leading 0.155mm lenticular pitch. In 2003, it will produce an even finer-pitch screen at 0.098mm lenticular pitch.

Toppan reports the screen is being used in some of the most popular MD-RPTVs on the market today.

In fact, Toppan sees the market for RPTVs changing rapidly from CRT-based system to microdisplay-based systems. This agrees well with the forecast published by Insight Media and McLaughlin Consulting Group (Microdisplay Forecast & Profile Report).

The FC-Screen is composed of three sheets: a Fresnel lens sheet, a lenticular sheet and a protective front sheet, which can include a vertical diffuser. Such screen construction is not uncommon, but the design details for the FC-Screen are a bit different, which accounts for its strong performance.

Overall, the Fresnel features a very fine pitch (0.1mm) of concentric cone prisms to offer high resolution and brightness. This element collects light from the projector, collimates it, and sends it to the lenticular array. The lenticular lens array has a 0.155 mm pitch and is used to focus light through a series of black stripes. Light is then diffused before passing out of the screen providing a wide viewing angle.

The performance improvement comes from a reduction in optical noise, which degrades contrast and causes color dispersion. Noise rays are generated from internal reflections and refraction between surfaces.

The FC-Screen uses a combination of lenticular lens design and black stripe design to reduce this optical noise. Usually, the lenticular lens shape is spherical, which causes rays off of the optical axis to not converge, generating optical distortion, as shown in the left drawing. Toppan changed the shape of the lenticular lenses to an aspherical ellipsoidal shape to focus all the light to a single point (right side of drawing). The result is a very crisp and well-defined line of light emanating from each lenticular element, instead of a poorly defined line of light surrounded by optical noise.

Because the line of light is so well defined, Toppan can use much wider black stripes in between each line of light. The stripe blocks skew rays and absorbs ambient light coming into the screen - both of which help to improve contrast.

Toppan was able to increase the width of the black stripes relative to the light passing area from a typical 50% aperture to about a 70% aperture, without sacrificing light throughput. In fact, researcher Kazuyoshi Ebina says they plan to increase the black stripe to 90% soon. Reflectivity of the black stripe is a low 0.1%.

Toppan notes that the FC-Screens can be manufactured with screen gains from 3.4 to 6.8, whereas most RPTV screens feature gains of about 3 to 5. The resulting viewing angles vary from 50 to 70 degrees. The signal-to-noise ratio is also improved from around 20 in most screens, to 45-60.

Toppan, Mari Ueno, [81] 3-3835-5187, mari.ueno@toppan.co.jp

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