CN114077149A - Projection screen - Google Patents

Abstract

The invention discloses a projection screen, which comprises a substrate structure and a plurality of optical structures. A plurality of optical structures are formed on one side of the substrate structure. Each optical structure is in a triangular prism shape. Each optical structure has a plurality of concave sections and a plurality of convex sections opposite to one end of the substrate structure, and the vertical distance between the end of each optical structure and the substrate structure at each concave section is smaller than the vertical distance between the end of each optical structure and the substrate structure at each convex section. The number and the position of the concave sections and the number and the position of the convex sections contained in the two optical structures adjacent to each other are different. By providing each optical structure with a plurality of concave sections and convex sections, the projection screen is not prone to generate moire (Mura).

Description

Projection screen

Technical Field

The invention relates to a projection screen, in particular to a projection screen capable of resisting ambient light.

Background

In a conventional projection screen for a projector, particularly a projection screen for a short-focus projector, a special optical structure is fabricated on the projection screen to avoid the influence of ambient light, so as to reduce the influence of the ambient light on the light beam projected on the projection screen by the projector. However, in the specific production process, the optical structure with the special design may have uneven surface thickness due to various reasons such as mold processing, molding, gluing, etc., and the projection screen has overlapped stripes (Mura), so that a user can easily see the dark or bright stripes of the projection screen when watching the projection screen.

Disclosure of Invention

The invention discloses a projection screen which is mainly used for solving the problem that a moire (Mura) phenomenon is easy to occur in the existing projection screen.

One embodiment of the present invention discloses a projection screen, which comprises: a first transparent body and a reflective layer. The first light-transmitting body is provided with a body part and a plurality of light guide parts, the light guide parts are adjacent to each other and convexly or concavely arranged on one side of the body part, and the sizes of the light guide parts are not completely the same; the reflection layer covers a whole or a part of an exposed surface of each of the light guide portions.

Preferably, the projection screen further includes a light shielding structure disposed on a side of the reflective layer opposite to the light guide portions, and the reflective layer is located between the light shielding structure and the first light-transmitting body.

Preferably, each light directing portion has a height between 5 microns and 500 microns.

Preferably, the projection screen further comprises a second light-transmitting body, and the first light-transmitting body is disposed on the second light-transmitting body and located between the second light-transmitting body and the reflective layer.

One embodiment of the present invention discloses a projection screen, which comprises: a light-shielding structure and a reflective layer. The shading structure body comprises a shading body and a plurality of light guide bodies arranged on the shading body, the plurality of light guide bodies are arranged on one side of the shading body in a protruding mode, or the plurality of light guide bodies are formed by recessing one side of the shading body in a concave mode, and the sizes of the plurality of light guide bodies are not identical; the reflecting layer completely covers or partially covers a bearing surface of the light guide bodies.

One embodiment of the present invention discloses a projection screen, which comprises: a substrate structure and a plurality of optical structures. One side of the substrate structure is defined as a functional surface; each optical structure is in a similar-angle column shape and is formed on the functional surface; each optical structure is provided with a bottom surface and two side surfaces, wherein one side surface is a light absorbing surface which has low reflectivity, and the other side surface is provided with a reflecting layer; one end of each optical structure opposite to the bottom surface is defined as an end part, the end part is provided with a plurality of concave sections, and a convex section is correspondingly formed between every two adjacent concave sections; the vertical distance between the end part and each concave section and the bottom surface is smaller than that between the end part and each convex section and the bottom surface; the difference between the longest vertical distance between the end portion and the bottom surface and the shortest vertical distance between the end portion and the bottom surface is between 2 micrometers and 20 micrometers; the position with the shortest vertical distance between the end part and the bottom surface of each optical structure is defined as the lowest point position, the position with the longest vertical distance between the end part and the bottom surface is defined as the highest point position, the highest point positions of two mutually adjacent optical structures are different, and the lowest point positions of two mutually adjacent optical structures are different.

Preferably, the maximum perpendicular distance between the end of each optical structure and the bottom surface at any one of the convex sections is defined as the highest point distance of the convex section; the distances of the highest points of the two convex sections corresponding to the two adjacent convex sections at the end parts of each optical structure are different from each other.

Preferably, the shortest vertical distance between the end of each optical structure and the bottom surface of any one of the concave sections is defined as a concave section lowest point distance; the distances between the lowest points of the two concave sections corresponding to the two concave sections adjacent to each other at the end of each optical structure are different from each other.

Preferably, the positions of the recessed sections respectively provided by two optical structures adjacent to each other are different from each other; the positions of the convex sections respectively provided by two optical structures adjacent to each other are different from each other.

Preferably, the number of the concave sections respectively provided by two optical structures adjacent to each other is different from each other; the two optical structures adjacent to each other have the number of the convex sections different from each other, respectively.

Preferably, there are at least 10 convex sections or at least 10 concave sections per centimeter of each optical structure.

Preferably, the perpendicular distance between the end of each optical structure and the bottom surface is inversely proportional to the radial width of the concave section or the radial width of the convex section.

Preferably, the longest perpendicular distance between the end of each optical structure and the bottom surface is between 280 microns and 300 microns.

Preferably, each optical structure is a light-transmitting structure, and the optical structure has a plurality of light-absorbing particles therein, and each light-absorbing particle is used for absorbing the light beam entering the optical structure; each optical structure is a triangular prism-like structure.

Preferably, the angle between the side surface of each optical structure having the reflective layer and the bottom surface is 15 to 60 degrees; the angle between the light absorbing surface and the bottom surface of each optical structure is 60-120 degrees.

In summary, the projection screen of the present invention greatly reduces the problem of the moire generated by the projection screen by designing the plurality of light guide portions with different sizes; the projection screen of the invention can greatly reduce the problem of the generation of the overlapped grains of the projection screen by the design that a plurality of convex sections and concave sections are formed at the end part of each optical structure, the positions of the lowest points of the end parts of two adjacent optical structures are different from each other, the positions of the highest points of the end parts of two adjacent optical structures are different from each other, and the like.

For a better understanding of the nature and technical content of the present invention, reference should be made to the following detailed description of the invention and the accompanying drawings, which are provided for illustration purposes only and are not intended to limit the scope of the invention in any way.

Drawings

Fig. 1 is a schematic view of a projection screen according to the present invention.

Fig. 2 is a schematic view of a projection screen according to a first embodiment of the present invention.

Fig. 3 is a schematic top view of a projection screen according to a first embodiment of the present invention.

Fig. 4 is a schematic partial cross-sectional view of a projection screen according to a first embodiment of the present invention.

Fig. 5A to 5C are schematic views illustrating a manufacturing process of the first embodiment of the projection screen according to the present invention.

Fig. 6 is a schematic partial cross-sectional view of a projection screen according to a second embodiment of the present invention.

Fig. 7 is a partial cross-sectional view of a projection screen according to a third embodiment of the present invention.

Fig. 8 is a partial cross-sectional view of a projection screen according to a fourth embodiment of the present invention.

Fig. 9 is a schematic partial cross-sectional view of a fifth embodiment of a projection screen of the present invention.

Fig. 10 is a schematic partial cross-sectional view of a projection screen according to a sixth embodiment of the present invention.

Fig. 11 is a partially enlarged schematic view of a seventh embodiment of the projection screen of the present invention.

Fig. 12 is a schematic view of a substrate structure and two optical structures of a seventh embodiment of a projection screen of the invention.

Fig. 13 is a partially enlarged side view schematically illustrating a seventh embodiment of the projection screen of the present invention.

Fig. 14 is a schematic partial cross-sectional view of a seventh embodiment of a projection screen of the present invention.

Fig. 15 is a schematic diagram of a side view of two optical structures of a seventh embodiment of a projection screen of the present invention.

Fig. 16 is a schematic manufacturing flow chart of a projection screen according to a seventh embodiment of the invention.

Fig. 17 and 18 are schematic views respectively illustrating a manufacturing apparatus of a seventh embodiment of the projection screen of the present invention.

Fig. 19 is a schematic view of a substrate structure and two optical structures of an eighth embodiment of a projection screen according to the invention.

Detailed Description

In the following description, reference is made to or shown in the accompanying drawings for the purpose of illustrating the general principles of the invention, and not by way of limitation, it is intended that all matter contained in the following description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

Referring to fig. 1 to 4, fig. 1 is a schematic view of a projection screen of the present invention, fig. 2 is a schematic view of a first embodiment of the projection screen of the present invention, fig. 3 is a schematic top view of the first embodiment of the projection screen of the present invention, and fig. 4 is a schematic partial cross-sectional view of the first embodiment of the projection screen of the present invention. The projection screen of the present invention is mainly used as a screen for a projector to project images, the size of the projection screen illustrated in the drawings of the present invention is only an exemplary form, and in practical applications, the size of the projection screen may be changed according to requirements, which is not limited herein.

The projection screen 2 of the present invention has a first transparent body 21 and a reflective layer 22. The first light-transmitting body includes a body portion 211 and a plurality of light-guiding portions 212, and the plurality of light-guiding portions 212 are formed on the body portion 211. The plurality of light guide portions 212 are disposed to protrude from the body portion 211. In practical applications, a portion of the light guide portions 212 may be substantially aligned along a first predetermined direction (e.g., the X-axis direction shown in fig. 2), a portion of the light guide portions 212 may be substantially aligned along a second predetermined direction (e.g., the Y-axis direction shown in fig. 2), and the plurality of light guide portions 212 form an array structure with an array arrangement; wherein the first predetermined direction and the second predetermined direction are staggered with each other.

The light guide portions 212 are not all the same size. In practical applications, the light guide portions 212 may be randomly formed on the main body portion 211, and have different sizes. By forming the light guide portions 212 with different sizes on the main body portion 211, the problem of moire (Mura) of the projection screen 2 can be greatly improved. In practical applications, the height of each light guide portion 212 may be between 5 micrometers (μm) and 500 micrometers, and the diameter of each light guide portion 212 may be between 5 micrometers and 500 micrometers. A gap F (as shown in fig. 3) between the light guide portions 212 may be, for example, between 1 micron and 100 microns, and the gaps F between any two light guide portions 212 may not be completely the same.

It is particularly emphasized that, in the drawings of the present embodiment, the shape of each light guide portion 212 is a hemisphere, but in practical applications, the shape of each light guide portion 212 is not limited thereto, and may be any shape according to requirements, for example, the cross-sectional profile of each light guide portion 212 may be a diamond shape, a semicircle shape, a drop shape, an ellipse shape, an arc shape, or the like in different embodiments.

In practical applications, the main body 211 and the light guide portions 212 may be integrally formed, or the main body 211 and the light guide portions 212 may be connected to each other by using a glue or a resin, or may be formed by hot pressing. The reflective layer 22 covers (or partially covers) an exposed surface 2121 of each of the light guide portions 212. The reflective layer 22 and the light guide portion 212 may be made of the same material or different materials. The reflective layer 22 is made of various coatings capable of reflecting light emitted from the projector, but not limited thereto.

In practical applications, the projection screen 2 may further include a second transparent body 23, and the first transparent body 21 may be disposed on the second transparent body 23 and located between the second transparent body 23 and the reflective layer 22. Further, the second light-transmitting body 23 may include a first surface 231 and a second surface 232 opposite to the first surface 231, the first light-transmitting body 21 may be disposed on the second surface 232 of the second light-transmitting body 23, and the first surface 231 of the second light-transmitting body 23 may be located on a side adjacent to the projector relative to the second surface 232. In other words, the second transparent body 23 may be located at a side adjacent to the projector compared to the first transparent body 21. In addition, according to the present invention, the first surface 231 of the second light-transmitting body 23 can be a plane. Furthermore, since the projection screen 2 provided by the present invention is applied to a front projection type (or referred to as a front projection type) projection structure, the first surface 231 of the second light transmissive body 23 can be used as a light incident surface and a light emitting surface of the projector.

In a specific implementation, the haze (haze) of the first light-transmitting body 21 and the haze of the second light-transmitting body 23 may not be the same, and the haze of the second light-transmitting body 23 may be greater than or equal to the haze of the first light-transmitting body 21. For example, the haze of the first light-transmitting body 21 may be between 0.5% and 30%, and the haze of the second light-transmitting body 23 may be between 10% and 80%, but not limited thereto. More specifically, the refractive index of the first light-transmitting body 21 may be between 1.42 and 1.66, and the light transmittance of the first light-transmitting body 21 may be between 85% and 99%. In addition, the material of the first light-transmitting body 21 may be Polyethylene terephthalate (PET), optical resin, acrylic (PMMA), Polyurethane resin (PU), Thermoplastic Polyurethane resin (TPU), etc., but is not limited thereto. The light transmittance of the second light-transmitting body 23 may be between 80% and 95%, and the second light-transmitting body 23 may be a diffusing light-transmitting body, and the material of the second light-transmitting body 23 may be, for example, glass, tempered glass, Polyethylene terephthalate (PET), a polymer material, a resin, a colloid, or a composite material thereof, which may be according to requirements. Through designs such as the luminousness that makes first printing opacity body 21 be greater than the luminousness of second printing opacity body 23, second printing opacity body 23 can produce the diffusion effect to indoor illumination lamps and lanterns or the ambient light that outdoor sunshine formed, and then can make projection curtain 2 be difficult to the reflection ambient light, and let the user can have the experience of watching of relative preferred. In addition, in order to make the projection screen 2 not easily reflect the ambient light, the second translucent body 23 may be formed of a black translucent body by using a black-doped pigment, in addition to a matte translucent body.

As shown in fig. 4, a projection light E generated by the projector is projected onto at least the second transparent body 23, the body portion 211 of the first transparent body 21, the light guide portion 212 of the first transparent body 21, and the reflective layer 22 disposed on the exposed surface 2121 of the light guide portion 212 in sequence, so that the light guide portion 212 of the first transparent body 21 can be a light chamber relative to the projection light E of the projector. Further, the projected light E can be reflected by the reflective layer 22 to form a reflected light reflected in the light chamber formed by the reflective layer 22 and the light guide portion 212, and the reflected light can also be reflected by the reflective layer 22 to form a projected light to generate a picture.

As shown in fig. 5A to 5C, the manufacturing process of the projection screen 2 of the present invention may be: as shown in fig. 5A, a concave mold is used to perform an over-mold process to manufacture a first light-transmitting body 21, where the first light-transmitting body 21 includes a body portion 211 and a plurality of light-guiding portions 212 with different sizes; as shown in fig. 5B, a reflective layer 22 is formed on the exposed surface 2121 of the light guide portions 212 opposite to the first light transmissive body 21; as shown in fig. 5C, finally, a second transparent body 23 is formed on the side of the first transparent body 21 opposite to the side where the light guide portions 212 are formed. In different embodiments, the projection screen 2 may not be provided with the second light-transmitting body 23. The concave mold has different diameters and depths of the cavities, and the concave mold can be turned over to manufacture a plurality of light guide portions 212 with different sizes.

Please refer to fig. 6, which is a partial cross-sectional view illustrating a projection screen according to a second embodiment of the present invention. The present embodiment is different from the previous embodiments in the following point: the projection screen 2 may further include a light shielding structure 24, wherein the light shielding structure 24 is formed on a side of each of the reflective layers 22 opposite to the light guide portions 212, and the reflective layers 22 are correspondingly located between the light shielding structure 24 and the light guide portions 212. The light-shielding structure 24 is used for absorbing the light beam projected by the projector, and the light beam projected by the projector to the projection screen 2 can be prevented from passing through the reflective layer 22 to cause light leakage by the arrangement of the light-shielding structure 24.

The present embodiment is different from the previous embodiments in that: the second light-transmitting body 23 may further include a plurality of diffusion particles 25, and the diffusion particles 25 may be particles of silicon dioxide (SiO2) or titanium dioxide (TiO2) or other polymer particles. Through the design of doping diffusion particle 25 in second printing opacity body 23, can promote the diffusion effect behind the ambient light entering second printing opacity body 23, and then can reduce projection screen 2 reflection ambient light by a wide margin, and let the viewer can have better viewing experience. In practical applications, the particle size of the diffusion particles 25 may be, for example, between 0.1 micrometers (μm) and 10 μm. It should be noted that in the embodiment where the second light transmissive body 23 is made of glass, a microstructure may be formed on a surface of the second light transmissive body 23 opposite to the first light transmissive body 21 by etching, sand blasting, spraying, or the like, and the microstructure has the same effect as the diffusion particles.

Please refer to fig. 7, which is a partial cross-sectional view illustrating a projection screen according to a third embodiment of the present invention. The present embodiment is different from the previous embodiments in the following point: the reflective layer 22 may include a resin 221 and a plurality of pigment particles 222 mixed in the resin 221. The resin 221 may be at least one selected from transparent acryl (polymethyl methacrylate, PMMA), Monomer (Monomer), epoxy resin, melamine formal resin, phenol resin, urea resin, urethane resin, etc., ethylene-based resin, acrylic resin, polyester resin, aromatic hydrocarbon resin, fluorine-containing resin, polyimide, etc. Further, the polyimide may be an aliphatic polyimide, a semi-aromatic polyimide, or an aromatic polyimide. The pigment particles 222 may be selected from at least one of titanium dioxide (TiO2), magnesium peroxide (MgO2), and Polytetrafluoroethylene (PTFE). The color of the pigment particles 222 may be white, and the reflective layer 22 does not absorb any of red, green and blue, so that the light beam projected onto the projection screen 2 by the projector can still maintain the original color after being reflected by the reflective layer 22.

Another difference between the present embodiment and the previous embodiment is that: a plurality of diffusion particles 25 may be provided between the reflective layer 22 and the first light transmitting body 21. By making the light transmittance of the first light-transmitting body 21 greater than that of the second light-transmitting body 23, and the like, and by setting the diffusion particles 25, the reflective layer 22 can be utilized by the projection screen 2, so that the light projected into the projection screen 2 and reflected by the projection screen 2 generates a Lambertian source-like scattering effect, and further, the uniformity of the light intensity of the projection screen 2 at each viewing angle can be improved.

Please refer to fig. 8, which is a partial cross-sectional view illustrating a projection screen according to a fourth embodiment of the present invention. The present embodiment is different from the first embodiment in the following point: the projection screen 2 may include the light shielding structure 24 but not the second light-transmitting body 23 (as shown in fig. 7), and the diffusion particles 25 may be doped in the first light-transmitting body 21. In a specific application of the present embodiment, the reflective layer 22 may be a Total Internal Reflection (TIR) layer made of metal such as aluminum, copper, silver, and chromium.

Please refer to fig. 9, which is a schematic partial cross-sectional view illustrating a fifth embodiment of a projection screen according to the present invention. The biggest difference between this embodiment and the aforementioned first embodiment is: the projection screen 2 of the present embodiment only includes a light-shielding structure 24 and a reflective layer 22. The light shielding structure 24 includes a light shielding body 241 and a plurality of light guiding members 242. The plurality of light guiding bodies 242 are formed on one side of the light shielding structure 24, and the plurality of light guiding bodies 242 may be provided integrally with the light shielding structure 24. The plurality of light guides 242 may have different sizes, and the plurality of light guides 242 may be arranged in a random manner. The reflective layer 22 is formed on one side of the light shielding structure 24 having the light guiding bodies 242, and the reflective layer 22 completely covers (or partially covers) a carrying surface 2421 of each of the light guiding bodies 242. By designing the light guide bodies 242 to have different sizes, the problem of moire (Mura) of the projection screen 2 can be greatly reduced.

Please refer to fig. 10, which is a schematic partial cross-sectional view illustrating a projection screen according to a sixth embodiment of the present invention. The present embodiment is different from the fifth embodiment in the following point: the light guide bodies 242A included in the projection screen 2 are formed by inwardly recessing one side of the light shielding body 241. The plurality of light guides 242A are not all the same size, and the plurality of light guides 242A are similarly arranged in a disordered manner. The reflective layer 22 is also disposed on one side of the light shielding structure 24, and a bearing surface 242A1 of each light guide 242A is provided with the reflective layer 22. The projection screen of the present embodiment can also greatly reduce the problem of moire (Mura) of the projection screen 2 by designing the light guide bodies 242A with different sizes.

Referring to fig. 11 and 12, fig. 11 is a partially enlarged schematic view of a projection screen according to a seventh embodiment of the present invention, and fig. 12 is a schematic view of a substrate structure and two optical structures of the seventh embodiment of the projection screen according to the present invention.

As shown in fig. 11, the projection screen 1 of the present invention has a substrate structure 10 and a plurality of optical structures 11. One side of the substrate structure 10 defines a functional surface 101. In practical applications, the substrate structure 10 may be made of, for example: polyethylene terephthalate (PET), Polycarbonate (PC), polymethyl methacrylate (PMMA), Polyurethane (PU), Thermoplastic Polyurethane (TPU), Phosphatidylethanolamine (PE), Thermoplastic Elastomer (TPE), silica gel, rubber, acrylic rubber, and the like, without limitation.

A plurality of optical structures 11 are formed on the functional side 101 of the substrate structure 10. Each optical structure 11 may be in a quasi-triangular prism shape, and in the drawings of the present embodiment, each optical structure 11 is in a quasi-triangular prism shape as an example, but not limited thereto. In the optical structure 11 of the present invention, the end portion 14 is not simply linear but undulates (described in detail later); therefore, each optical structure 11 of the present invention is not a triangular prism structure in terms of strict geometric definition, but each optical structure 11 of the present invention has an appearance similar to a triangular prism as a whole, and thus each optical structure 11 of the present invention is referred to herein as a triangular prism-like shape. Briefly, the meaning of the quasi-angular column referred to herein is: although the overall structure does not conform to the geometric definition of a strict triangular prism, the overall structure still exhibits an appearance that approximates the geometric definition of a strict triangular prism.

The transmittance, refractive index, etc. of the optical structure 11 can be varied according to the requirement, and are not limited herein. Each optical structure 11 may be integrally formed with the substrate structure 10, or the optical structures 11 may be made of the same material as the substrate structure 10 and formed sequentially in stages during the manufacturing process, but not limited thereto. In the embodiment where the substrate structure 10 is disposed non-integrally with the optical structures 11, the material of the substrate structure 10 can be any material capable of supporting the optical structures 11, and is not limited herein.

As shown in fig. 11 and 12, each optical structure 11 has a bottom surface 111 and two side surfaces 112, 113, wherein one side surface 112 is used as a light absorbing surface 112A, the light absorbing surface 112A has low reflectivity, and the other side surface 113 has a reflective layer 13. The bottom surface 111 of the optical structure 11 is located on the functional surface 101 of the substrate structure 10. Specifically, each optical structure 11 may be made of a material (the material itself may be transparent or low-transparent) doped with light-absorbing particles (e.g., carbon black, etc.), and light beams entering the optical structure 11 from the light-absorbing surface 112A will not be easily reflected outward. In various applications, each optical structure 11 may also be formed with microstructures on the light-absorbing surface 112A to reduce the ability of the light-absorbing surface 112A to reflect light. In fig. 11 and 12, the black dots in the optical structure 11 are the light absorbing particles.

The reflective layer 13 is applied to the other side 113 of the optical structure 11, and the reflective layer 13 is used for reflecting the light beam. In practical applications, the reflective layer 13 is made of white material, for example, and the reflective layer 13 may be formed on the side surface 113 of the optical structure 11 in a coating manner. In various embodiments, each optical structure 11 may be additionally coated with a light-absorbing layer on the light-absorbing surface 112A.

Please refer to fig. 13, which is a partially enlarged side view of the projection screen of the present invention, wherein three imaginary lines in fig. 13 respectively represent paths of the ambient light S, the light beam P emitted by the projector, and the light beam R reflected by the projection screen. As described above, by providing the light absorbing particles in the optical structure 11, one side of the optical structure 11 is formed as the light absorbing surface 112A, when the ambient light S enters the light absorbing surface 112A of the optical structure 11, the ambient light S is not easily reflected, and the light beam projected to the projection screen 1 by the projector is not easily affected by the ambient light S. Thus, the user only needs to correctly position the projection screen 1 (for example, to make the light absorbing surface 112A of each optical structure 11 face the ceiling), so as to greatly reduce the influence of the ambient light S on the screen of the projection screen 1.

In order to better avoid the ambient light S from affecting the image of the projection screen 1, as shown in fig. 13, in the embodiment that each optical structure 11 is a triangular prism-like structure, an included angle θ 1 between the light-absorbing surface 112A and the bottom surface 111 of each optical structure 11 may be between 60 degrees and 120 degrees; the angle θ 2 between the side surface 113 of each optical structure 11 coated with the reflective layer 13 and the bottom surface 111 may be between 15 degrees and 60 degrees.

As shown in fig. 13, when the projection screen 1 is hung, the light-absorbing surface 112A of each optical structure 11 faces the ceiling, and the ambient light S from the ceiling easily passes through the light-absorbing surface 112A and directly enters the optical structure 11, and the ambient light S entering the optical structure 11 is not easily reflected to the eyes of the user, so that the user can easily see the light beam P reflected by the reflective layer 13 and emitted from the projector to the projection screen 1. Therefore, through the above design of the optical structure 11, the light absorbing surface 112A and the reflective layer 13, the light beam projected to the projection screen 1 by the projector is not easily affected by the ambient light S, and the user can view the image with better color contrast and gain ratio on the projection screen 1. The reflective layer 13 may incorporate diffusing particles to provide scattering.

Referring to fig. 12 and 14, fig. 12 is a schematic view of a substrate structure 10 and two optical structures 11 adjacent to each other; wherein each optical structure 11 is not provided with a reflective layer 13. As shown in fig. 12, an end of each optical structure 11 opposite to the bottom surface 111 is defined as an end portion 14. The end portion 14 has a plurality of concave sections 14A, and two concave sections 14A adjacent to each other have a convex section 14B formed therebetween.

FIG. 14 is a schematic cross-sectional view of a solid surface where one of the optical structures 11 intersects a cut surface. The cutting plane is a plane perpendicular to the bottom surface 111 and passing through the end 14; the line segment of the cut plane intersecting the end 14 defines a ridge 15 and the line segment of the cut plane intersecting the base 111 defines a base line 16. The ridge 15 is in a shape of a relief, and the perpendicular distance H1 between the ridge 15 and the bottom line 16 in each concave section 14A is smaller than the perpendicular distance H2 between the ridge 15 and the bottom line 16 in each convex section 14B; that is, the vertical distance between the end 14 of each optical structure 11 and the bottom 111 at the concave section 14A is smaller than the vertical distance between the end 14 of each optical structure 11 and the bottom 111 at the convex section 14B.

The maximum vertical distance between the end 14 of each optical structure 11 and the bottom surface 111 at any protruding section 14B is defined as the highest point distance of a protruding section; the distances between the highest points of the two protruding sections corresponding to the two protruding sections 14B adjacent to each other at the end portion 14 of each optical structure 11 are different from each other. The shortest vertical distance between the end 14 of each optical structure 11 and the bottom 111 at any one of the recessed sections 14A is defined as a recessed section lowest point distance; the distances between the lowest points of the two concave sections corresponding to the two concave sections 14A adjacent to each other at the end portion 14 of each optical structure 11 are different from each other. That is, as shown in fig. 14, the longest vertical distances H2, H4 of two protruding sections adjacent to each other are different from each other, and the shortest vertical distances H1, H3 of two recessed sections adjacent to each other are different from each other. It should be noted that the difference between the longest vertical distance HH between the edge line 15 and the bottom line 16 and the shortest vertical distance LH between the edge line 15 and the bottom line 16 is between 2 micrometers and 20 micrometers, i.e., the average difference of the height fluctuation of the edge line 15 falls between 2 micrometers and 20 micrometers; that is, the difference between the longest vertical distance between the end portion 14 and the bottom surface 111 of each optical structure 11 and the shortest vertical distance between the end portion 14 and the bottom surface 111 is between 2 micrometers and 20 micrometers. That is, the ridge 15 is designed at the time of manufacturing each optical structure 11, and the ridge 15 is not a defect caused by the tolerance of the related tool when each optical structure 11 is manufactured.

More specifically, the optical structure 11 of the present invention is manufactured by ultra-precision machining, which generally has a machining tolerance of about 1 micron, that is, if the average difference of the height of the ridge 15 falls within about 1 micron, the height of the ridge 15 may be caused by the tolerance of the related machining equipment. In practical applications, the end portion 14 of each optical structure 11 may include at least 10 concave sections 14A or at least 10 convex sections 14B within each centimeter. That is, the number of the concave sections 14A and the number of the convex sections 14B of each optical structure 11 may be designed intentionally.

Please refer to fig. 15, which is a schematic diagram showing two adjacent optical structures after their cross-sectional views are superimposed. In practical applications, the undulations of the ridges 15A, 15B of two optical structures 11 adjacent to each other are substantially completely different. That is, the perpendicular distance of each section of the ridge line 15A from the bottom line 16 in fig. 6 is substantially different from the perpendicular distance of each section of the ridge line 15B from the bottom line 16; the position of the longest vertical distance HH1 between the edge line 15A and the bottom line 16 is different from the position of the longest vertical distance HH2 between the edge line 15B and the bottom line 16; the shortest vertical distance LH1 between the edge line 15A and the bottom line 16 is different from the shortest vertical distance LH2 between the edge line 15B and the bottom line 16; the number of recessed sections of the ridge 15A and the number of recessed sections of the ridge 15B are different; the number of the projecting sections of the ridge 15A and the number of the projecting sections of the ridge 15B are different from each other. In short, the end portion 14 of each optical structure 11 has a shape substantially different from the shape of the end portion 14 of the adjacent optical structure 11.

More specifically, in fig. 15, if the position having the longest vertical distance between the edge line 15A and the bottom line 16 is defined as a first highest point position, and the position having the longest vertical distance between the edge line 15B and the bottom line 16 is defined as a second highest point position, the distance L1 between the first highest point position and the corresponding end of the optical structure 11 is different from the distance L2 between the second highest point position and the corresponding end of the optical structure 11. In contrast, the distance between the position having the shortest vertical distance between the edge line 15A and the bottom line 16 and the one end of the corresponding optical structure 11, and the distance between the position having the shortest vertical distance between the edge line 15B and the bottom line 16 and the one end of the corresponding optical structure 11 are different from each other. In other words, if the position having the shortest vertical distance between the end portion 14 and the bottom surface 111 of each optical structure 11 is defined as the lowest point position, and the position having the longest vertical distance between the end portion 14 and the bottom surface 111 is defined as the highest point position, the highest point positions of two optical structures 11 adjacent to each other are different, and the lowest point positions of two optical structures 11 adjacent to each other are different.

Referring to fig. 16 to 19 together, fig. 16 is a schematic flow chart illustrating a method for manufacturing a projection screen according to the present invention, and fig. 17 and 18 are schematic diagrams illustrating a method for manufacturing a projection screen according to the present invention.

As shown in fig. 16, the method for manufacturing a projection screen of the present invention includes:

a mold roller manufacturing step S1: forming a plurality of grooves B1 (shown in fig. 17) on a mold roller B by using a cutter a; the cutter A is in a pyramid shape; continuously and randomly moving the cutter A a predetermined distance in a direction approaching or separating from the mold roller B during the process of forming each of the grooves B1 so that different sections of each of the grooves have different depths; wherein the predetermined distance is between 2 microns and 20 microns; when the shape of the cutter is fixed, the processing width with inconsistent depth can be relatively changed.

An optical structure forming step S2: installing the mold roller B beside a guide wheel C, and allowing a substrate structure 10 with a to-be-cured adhesive 11A formed on the surface to pass between the mold roller B and the guide wheel C, so as to shape the to-be-cured adhesive 11A into a plurality of semi-cured structures 11B by using the plurality of grooves B1 of the mold roller B (shown in fig. 18);

a curing step S3: curing the plurality of semi-cured structures 11B formed on the substrate structure 10 to form a plurality of optical structures 11 on the substrate structure 10; wherein each optical structure 11 is in a triangular prism-like shape; as shown in fig. 18, in practical applications, for example, an ultraviolet curing device U may be disposed on the mold roller B to irradiate the plurality of semi-curing structures 11B on the substrate structure 10 for curing;

a reflective layer forming step S4: and coating a reflective colloid on the other side surface of each optical structure and curing the reflective colloid to form a reflective layer.

In the step S1, the tool a is controlled by a computer device to move continuously toward or away from the die roller B by a predetermined distance (for example, between 2 microns and 20 microns) in a random number manner. Specifically, in the mold roller manufacturing step S1, assuming that the original cutting feed amount of the tool a is preset to 300 micrometers, in the mold roller manufacturing step S1, the tool a may be randomly increased or decreased by 3 micrometers to 10 micrometers on the basis of 290 micrometers by using the computer; that is, the feed of the tool a at a certain time point may be 310 microns, the feed at the next time point (for example, the next millisecond) may be 290 microns, and the feed at the next time point (for example, the next millisecond) may be 295 microns, so that each of the grooves B1 on the mold roller B has different depths at different sections, and the perpendicular distance between the end 14 and the bottom 111 of each of the optical structures 11 finally manufactured through the other steps may be approximately 280 microns to 300 microns; of course, the vertical distance between the end 14 and the bottom 111 of each optical structure 11 actually manufactured may be between 279 micrometers and 301 micrometers, considering the tolerance of the processing tool.

Specifically, in the step S1, the Tool a is controlled by the computer device to move toward or away from the die roller B continuously by a random number, the predetermined distance is designed according to the maximum vibration frequency limit of the device connected to the Tool a, for example, if the die roller B is turned by a conventional Fast Tool Servo (Fast Tool Servo) turning device to form a groove on the die roller B, the predetermined distance may be 2 to 20 micrometers.

Referring to fig. 14 again, the imaginary line shown in the figure shows the ridge (hereinafter referred to as the predetermined ridge Q) of the optical structure 11 finally manufactured if the tool does not approach or depart from the die roller randomly; in fig. 14, the continuous positions where the vertical distance between the edge line 15 and the bottom line 16 is lower than the default edge line Q are the recessed sections 14A, and the continuous positions where the vertical distance between the edge line 15 and the bottom line 16 is higher than the default edge line Q are the protruding sections 14B.

It should be noted that, as shown in fig. 17, in practical applications, the depth dimension of the groove B1 to be formed on the die roller B is measured in microns, so that it is relatively easy to control the cutter a to randomly move 3 microns to 10 microns in the direction X toward or away from the die roller B, and it is relatively difficult or even impossible to control the cutter to randomly move 3 microns to 10 microns in the length direction Y of the die roller B. That is, the contents of the mold roll manufacturing step S1 are easily embodied, but it is relatively difficult to embody the contents by moving the cutter a in the longitudinal direction of the mold roll B.

The substrate structure 10 in the step S2 of forming the optical structure may be the same as the to-be-cured adhesive 11A, and the substrate structure 10 is a cured structure, and the to-be-cured adhesive 11A is colloidal. Of course, in different embodiments, the substrate structure 10 and the to-be-cured adhesive 11A may also be composed of different materials, which is not limited herein.

In this way, by the method for manufacturing the projection screen, the projection screen of the optical structure 11 having the end portion 14 with the plurality of concave sections 14A and the plurality of convex sections 14B can be manufactured. It should be noted that the optical structure forming step S2 is an example of a Roll-to-Roll (Roll) forming method, but not limited thereto.

It should be noted that, in the projection screen 1 manufactured by the above-mentioned method for manufacturing a projection screen, as seen in the cross-sectional view shown in fig. 14, the radial width W1 and the longitudinal recess depth D1 of each recess section 14A are inversely proportional, and the radial width W2 and the longitudinal projection height D2 of each projection section 14B are inversely proportional. That is, the radial width of the recessed section 14A is wider as the depth of the section where the ridge 15 is lower than the predetermined ridge Q is deeper, whereas the radial width of the recessed section 14A is narrower as the depth of the section where the ridge 15 is lower than the predetermined ridge Q is shallower; in contrast, the higher the height of the section of the ridge 15 higher than the predetermined ridge Q, the wider the radial width of the recessed section 14A, and the lower the height of the section of the ridge 15 higher than the predetermined ridge Q, the narrower the radial width of the recessed section 14A. In other words, the perpendicular distance between the end 14 and the bottom surface 111 of each optical structure 11 is inversely proportional to the radial width of the recessed section 14A or the radial width of the protruding section 14B.

It should be noted that the shape of the end portion 14 of each optical structure 11 of the projection screen 1 manufactured by the method for manufacturing a projection screen may also be changed according to the shape of the tool, and the ridge 15 shown in fig. 5 of this embodiment is only an exemplary shape, for example, each concave section or each convex section in fig. 5 is substantially arc-shaped, and each concave section or each convex section may also be pointed in embodiments using different tools.

Referring to fig. 15 again, in the actual application of the projection screen 1 manufactured by the method for manufacturing a projection screen, in the step S1 for manufacturing the mold roller, the computer device controls the cutter a to approach or leave the mold roller B at a predetermined distance in a random number manner, the used random number seeds (random seed) are different from each other, so that the number and the position of the concave sections 14A and the convex sections 14B of the end portions 14 of the two optical structures 11 adjacent to each other of the finally manufactured projection screen 1 are different from each other.

As described above, the optical structures 11 of the projection screen 1 of the present invention have the end portions 14 with different shapes, and particularly, the end portions 14 of two adjacent optical structures 11 have completely different shapes (i.e. have different numbers of concave sections, different numbers of convex sections, different maximum point positions, and different minimum point positions), so that after the optical structures 11 of the projection screen 1 are coated with the reflective layer 13, no moire (i.e. Mura) is generated due to the existing error mode of the manufacturing tool, that is, the projection screen 1 of the present invention is not prone to generate the streak-like defect as the conventional projection screen is prone to generate.

Furthermore, since the size of the optical structure is small, when the reflective colloid is coated on one side of the optical structure, it is difficult to precisely control the thickness of the reflective colloid coated on each section of the side surface of the optical structure to be the same in the prior art, and therefore, after the reflective colloid is cured, the side surface of the optical structure will have a reflective structure with non-uniform thickness, and the conventional projection screen will have the problem of moire (Mura). The projection screen 1 of the present invention can improve or even solve the problem of the overlapping lines of the conventional projection screen by making the end portion 14 of each optical structure 11 have the disordered undulation.

Please refer to fig. 19, which is a schematic diagram of a substrate structure and two optical structures of an eighth embodiment of a projection screen according to the present invention. As shown in the figure, the biggest difference between the present embodiment and the previous embodiment is: the end 14 of each optical structure 11 may also have a plurality of notches 17, each notch 17 being formed by the end 14 being recessed in the direction of the substrate structure 10. In practical applications, the number of the notches 17 included in each optical structure 11 may be designed according to requirements, and is not limited herein, and the shape of each notch 17 included in each optical structure 11 may also be changed according to requirements, and is not limited herein. Through the design of disposing a plurality of notches 17 on each optical structure 11, the probability of generating overlapping stripes on the projection screen can be further reduced.

In summary, compared to the existing projection screen, especially the projection screen with the function of resisting the ambient light, the projection screen of the present invention is not easy to generate the problem of overlapping stripes, and the projection screen of the present invention can have better color performance compared to the existing projection screen.

The above description is only a preferred embodiment of the present invention, and not intended to limit the scope of the present invention, so that equivalent technical changes made by using the contents of the present specification and the drawings are included in the scope of the present invention.

Claims (15)

1. A projection screen, comprising:

the first light-transmitting body is provided with a body part and a plurality of light guide parts, the light guide parts are adjacently arranged on one side of the body part in a protruding or recessed mode, and the light guide parts are not identical in size;

and the reflecting layer completely covers or partially covers an exposed surface respectively included by the light guide parts.

2. The projection screen of claim 1, further comprising a light-shielding structure disposed on a side of the reflective layer opposite to the light-guiding portions, wherein the reflective layer is disposed between the light-shielding structure and the first light-transmitting body.

3. The projection screen of claim 1, wherein each light guide portion has a height of between 5 microns and 500 microns.

4. The projection screen of claim 1, further comprising a second light transmissive body, wherein the first light transmissive body is disposed on the second light transmissive body and between the second light transmissive body and the reflective layer.

5. A projection screen, comprising:

the shading structure body comprises a shading body and a plurality of light guide bodies arranged on the shading body, the plurality of light guide bodies are arranged on one side of the shading body in a protruding mode, or the plurality of light guide bodies are formed by recessing one side of the shading body in a concave mode, and the sizes of the plurality of light guide bodies are not identical; and

and the reflecting layer completely covers or partially covers a bearing surface of the light guide bodies.

6. A projection screen, comprising:

a substrate structure, one side of which is defined as a functional surface;

the optical structures are in a similar-angle column shape and are formed on the functional surface; each optical structure is provided with a bottom surface and two side surfaces, wherein one side surface is a light absorbing surface which has low reflectivity, and the other side surface is provided with a reflecting layer;

one end of each optical structure opposite to the bottom surface is defined as an end part, the end part is provided with a plurality of concave sections, and a convex section is correspondingly formed between every two adjacent concave sections; the perpendicular distance between the end part and the bottom surface of each concave section is smaller than that between the end part and the bottom surface of each convex section; the difference between the longest vertical distance between the end portion and the bottom surface and the shortest vertical distance between the end portion and the bottom surface is between 2 micrometers and 20 micrometers;

the position of the shortest vertical distance between the end portion and the bottom surface of each optical structure is defined as a lowest point position, the position of the longest vertical distance between the end portion and the bottom surface is defined as a highest point position, the highest point positions of two mutually adjacent optical structures are different, and the lowest point positions of two mutually adjacent optical structures are different.

7. The projection screen of claim 6, wherein the maximum perpendicular distance between the end of each optical structure and the bottom surface at any one of the protruding sections is defined as a highest point distance of a protruding section; the distances of the highest points of the two convex sections corresponding to the two adjacent convex sections of the end part of each optical structure are different from each other.

8. The projection screen of claim 6, wherein the shortest vertical distance between the end of each optical structure and the bottom surface of any one of the recessed sections is defined as a recessed section lowest point distance; the distances between the lowest points of the two concave sections corresponding to the two concave sections adjacent to each other at the end of each optical structure are different from each other.

9. The projection screen of claim 7 or 8, wherein the positions of the recessed sections of two adjacent optical structures are different from each other; the positions of the convex sections respectively possessed by two optical structures adjacent to each other are different from each other.

10. The projection screen of claim 7 or 8, wherein the number of the concave sections of two adjacent optical structures is different from each other;

the number of the convex sections of each of two optical structures adjacent to each other is different from each other.

11. The projection screen of claim 7 or 8, wherein each of the optical structures has at least 10 convex segments or at least 10 concave segments per centimeter.

12. The projection screen of claim 11, wherein the perpendicular distance between the end of each optical structure and the bottom surface is inversely proportional to the radial width of the recessed section or the radial width of the protruding section.

13. The projection screen of claim 12, wherein the longest vertical distance between the end of each of the optical structures and the bottom surface is between 280 microns and 300 microns.

14. The projection screen of claim 13, wherein each of the optical structures is a light-transmissive structure and the optical structure has a plurality of light-absorbing particles therein, each of the light-absorbing particles being configured to absorb a light beam entering the optical structure; each optical structure is a triangular prism-like structure.

15. The projection screen of claim 14, wherein the side surface of each optical structure having the reflective layer is at an angle of 15 to 60 degrees with respect to the bottom surface; the included angle between the light absorbing surface and the bottom surface of each optical structure is 60-120 degrees.

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