CN114624952A

CN114624952A - Projection screen and manufacturing method thereof

Info

Publication number: CN114624952A
Application number: CN202210254415.6A
Authority: CN
Inventors: 张海鹏
Original assignee: Qingdao Hisense Laser Display Co Ltd
Current assignee: Qingdao Hisense Laser Display Co Ltd
Priority date: 2022-03-15
Filing date: 2022-03-15
Publication date: 2022-06-14

Abstract

The application discloses a projection screen and a manufacturing method thereof, relates to the technical field of projection display, and is used for solving the problem that black spots are easy to appear on the surface of the projection screen. The projection screen includes a reflective layer, a Fresnel lens layer, a functional layer, pigment particles, and an improvement material. The Fresnel lens layer and the reflecting layer are arranged in a stacked mode, and the functional layer is arranged on one side, far away from the reflecting layer, of the Fresnel lens layer in a stacked mode. The pigment particles are distributed in at least one of the Fresnel lens layer and the functional layer. The improved material is added into the materials of the functional layer distributed with pigment particles and the Fresnel lens layer, and comprises at least one of a surfactant and a dispersant. The projection screen is used for displaying images projected by the projector.

Description

Projection screen and manufacturing method thereof

Technical Field

The application relates to the technical field of projection display, in particular to a projection screen and a manufacturing method thereof.

Background

In the field of projection display technology, projectors are commonly used in conjunction with projection screens. The light emitted by the projector is projected onto the projection screen, and reaches the eyes of the audience after being reflected by the projection screen, so that the audience can watch an image formed by the light on the surface of the projection screen.

However, in a humid environment, black spots are easily formed on the surface of the projection screen, thereby affecting the projection effect of the projection screen and reducing the viewing experience of the audience.

Disclosure of Invention

The application provides a projection screen and a manufacturing method thereof, which are used for solving the problem that black spots are easy to appear on the surface of the projection screen.

In order to achieve the purpose, the technical scheme is as follows:

in one aspect, an embodiment of the present application provides a projection screen, which includes a reflective layer, a fresnel lens layer, a functional layer, pigment particles, and an improvement material. The Fresnel lens layer and the reflecting layer are arranged in a stacked mode, and the functional layer is arranged on one side, far away from the reflecting layer, of the Fresnel lens layer in a stacked mode. The pigment particles are distributed in at least one of the Fresnel lens layer and the functional layer. The improved material is added into the materials of the functional layer distributed with pigment particles and the Fresnel lens layer, and comprises at least one of a surfactant and a dispersant.

The projection screen provided by the embodiment of the application comprises a reflection layer, a Fresnel lens layer and a functional layer which are arranged in a stacked mode. When reaching the projection screen, the light rays projected by the projector sequentially pass through the functional layer and the Fresnel lens layer and then reach the reflecting layer. Under the reflection of the reflection layer, the light rays are reflected to the Fresnel lens layer and the functional layer in sequence and finally reflected to eyes of audiences, and the audiences can watch images on the projection screen.

In addition, the projection screen provided by the embodiment of the application further comprises pigment particles and an improved material, and the pigment particles and the improved material can be distributed in at least one of the fresnel lens layer and the functional layer in the projection screen. Because the improved material comprises at least one of the surfactant and the dispersing agent, the tension of the base materials of the Fresnel lens layer and the functional layer can be reduced, the repulsive force between the pigment particles can be increased, the binding force between the pigment particles and the base materials of the Fresnel lens layer and the functional layer is increased, and the pigment particles in the Fresnel lens layer and the functional layer can be kept in a dispersed state and are not easy to agglomerate. Therefore, the projection screen provided by the embodiment of the application can enable pigment particles to be well dispersed in at least one layer of the functional layer and the Fresnel lens layer, agglomeration is not easy to occur, the pigment particles are not easy to migrate to the surface of the projection screen, the projection effect of the projection screen and the appearance quality of the projection screen are guaranteed, and the watching experience of a user is improved.

In some embodiments, the material of the functional layer having the pigment particles distributed thereon and the fresnel lens layer comprises a shadowless glue.

In some embodiments, the surfactant comprises an ionic surfactant that is used to charge the surface of the pigment particles to repel the pigment particles from each other.

In some embodiments, the ionic surfactant comprises at least one of a fatty amine and a quaternary ammonium salt.

In some embodiments, the dispersant comprises an inorganic dispersant. One end of the inorganic dispersant is adsorbed on the surface of the pigment particles, and the other end is dissolved in the functional layer distributed with the pigment particles and the material in the Fresnel lens layer.

In some embodiments, the inorganic dispersant comprises at least one of a polyphosphate and a hydroxyamine group.

In some embodiments, the mass ratio of pigment particles to modifying material is 5: 1-10: 1.

in some embodiments, the mass fraction of the pigment particles in the fresnel lens layer and the functional layer is 5% to 10%.

In another aspect, an embodiment of the present application provides a method for manufacturing any one of the projection screens described above, where the method includes: and mixing the improved material with the base material to obtain the mixed material. Pigment particles are added to the mixed material. The method further comprises the following steps: forming a fresnel lens layer made of a mixed material to which pigment particles are added on one side of the functional layer; and forming a reflecting layer on one side of the Fresnel lens layer far away from the functional layer. Or, the method further comprises: forming a functional layer made of a mixed material to which pigment particles are added on one side of the Fresnel lens layer; and forming a reflecting layer on one side of the Fresnel lens layer far away from the functional layer.

The technical effect of the method for manufacturing the projection screen is the same as that of the projection screen, and the details are not repeated here.

In some embodiments, the base material is a shadowless glue; forming a fresnel lens layer made of a mixed material to which pigment particles are added on the functional layer side includes: coating a shadowless glue mixed with pigment particles and an improved material on one side of the functional layer; impressing the shadowless adhesive by using a mold to obtain a shadowless adhesive layer with a Fresnel microstructure; and curing the shadowless adhesive layer by using a UV light source lamp to obtain the Fresnel lens layer. Forming a functional layer made of a mixed material to which pigment particles are added on the fresnel lens layer side includes: coating a shadowless adhesive mixed with pigment particles and an improved material on one side of the Fresnel lens layer away from the reflecting layer; and curing the shadowless glue by using a UV light source lamp to obtain the functional layer.

Drawings

In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings required to be used in the description of the embodiments are briefly introduced below, and it is obvious that the drawings in the description below are only some embodiments of the present application, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.

Fig. 1 is a schematic view illustrating a usage status of a projection apparatus according to an embodiment of the present disclosure;

fig. 2 is a schematic structural diagram of a projection screen according to an embodiment of the present disclosure;

fig. 3 is a schematic structural diagram of an interior of a functional layer according to an embodiment of the present disclosure;

fig. 4 is a schematic structural diagram of the interior of another functional layer provided in an embodiment of the present application;

fig. 5 is a schematic structural diagram of the interior of another functional layer provided in an embodiment of the present application;

fig. 6 is a schematic structural diagram of another projection screen provided in an embodiment of the present application;

FIG. 7 is a schematic structural diagram of a surface layer provided in an embodiment of the present disclosure;

FIG. 8 is a schematic structural diagram of another surface layer provided in an embodiment of the present application;

FIG. 9 is a schematic view of the micro-lenses on the surface layer shown in FIG. 8 after being atomized;

fig. 10 is a schematic structural diagram of another projection screen provided in an embodiment of the present application;

fig. 11 is a schematic structural diagram of another projection screen provided in an embodiment of the present application;

fig. 12 is a schematic structural diagram of another projection screen provided in an embodiment of the present application;

fig. 13 is a schematic structural diagram of a fresnel lens layer according to an embodiment of the present disclosure;

fig. 14 is a schematic structural diagram of another fresnel lens layer provided in the embodiments of the present application;

fig. 15 is a schematic structural diagram of a reflective layer according to an embodiment of the present disclosure;

FIG. 16 is a schematic structural diagram of another reflective layer provided in the embodiments of the present application;

fig. 17 is a first flowchart illustrating a method for manufacturing a projection screen according to an embodiment of the present application;

fig. 18 is a second flowchart illustrating a method for manufacturing a projection screen according to an embodiment of the present application;

fig. 19 is a third schematic flowchart illustrating a method for manufacturing a projection screen according to an embodiment of the present application;

fig. 20 is a fourth flowchart illustrating a manufacturing method of a projection screen according to an embodiment of the present application.

Reference numerals:

100-a projection device; 1-a projection screen; 11-a reflective layer; 12-a fresnel lens layer; 13-a functional layer; 14-pigment particles; 15-modifying material; 151-surfactant; 152-a dispersant; 16-a diffusion layer; 17-a surface layer; 18-a substrate layer; 181-light-transmitting bumps; 19-an adhesive layer; 2-a projector; 21-incident light; 22-outgoing rays; 3-audience members; 40-diffusing particles; 50-micro lens.

Detailed Description

The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are only a part of the embodiments of the present application, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.

In the description of the present application, it is to be understood that the terms, "upper", "lower", "front", "inner", "center", and the like, indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, are only for convenience in describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed in a specific orientation, and be operated, and thus, should not be construed as limiting the present application.

In the embodiments of the present application, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising an … …" does not exclude the presence of other like elements in a process, method, article, or apparatus that comprises the element.

In the embodiments of the present application, the words "exemplary" or "such as" are used herein to mean serving as an example, instance, or illustration. Any embodiment or design described herein as "exemplary" or "e.g.," is not necessarily to be construed as preferred or advantageous over other embodiments or designs. Rather, use of the word "exemplary" or "such as" is intended to present relevant concepts in a concrete fashion.

In the related art, in order to improve the resistance of the projection screen against the ambient light, pigment particles are generally added inside the projection screen, and the pigment particles can absorb the ambient light from the outside. Therefore, when the projection screen is used, light of ambient light enters the inside of the projection screen, passes through the pigment particles and is absorbed by the pigment particles, so that the contrast of the projection screen is better, and a viewer can see a clear image on the projection screen.

However, the pigment particles have a small particle size and a high specific surface area, resulting in a high surface energy. It will be appreciated that materials with higher surface energies will generally lower their surface energy automatically to achieve a stable state. In the pigment particles, in order to reduce the surface energy of the pigment particles, the pigment particles are adsorbed and agglomerated to form pigment particles with larger particle sizes, so as to reduce the surface energy of the pigment particles. The agglomerated pigment particles with larger particle size are easy to migrate from the inside of the projection screen to the surface of the projection screen in a hot and humid environment to form black spots, which affects the projection effect and appearance of the projection screen.

Accordingly, an embodiment of the present application provides a projection apparatus, and referring to fig. 1, fig. 1 is a schematic view illustrating a use state of the projection apparatus 100 according to the embodiment of the present application. Projection device 100 may include a projection screen 1 and a projector 2. In use of the projection apparatus 100, the projector 2 may be placed in front of and below the projection screen 1, and the viewer 3 may be positioned in front of the projection screen 1 and look at the projection screen 1. Incident light 21 emitted by the projector 2 is irradiated to the projection screen 1, and the incident light 21 is reflected by the projection screen 1 to finally form emergent light 22 to be irradiated to the audience 3, and simultaneously, images are formed in the projection screen 1.

The projector 2 shown in fig. 1 may include a laser, which may be one of a monochromatic laser, a dichroic laser, and a three-color laser. The three-color laser can emit blue laser, red laser and green laser. The wavelength of blue laser light emitted from the laser may be set to a range of 430nm-460nm, the wavelength of green laser light emitted may be set to a range of 500nm-540nm, and the wavelength of red laser light emitted may be set to a range of 610nm-650 nm.

Since the three-color laser has the advantages of color fidelity and high color gamut, the laser in the projector 2 provided by the embodiment of the present application can be selected from the three-color laser. Of course, the laser in the projector 2 provided in the embodiment of the present application may also be a monochromatic laser or a dichroic laser.

In the technical field of projection display, especially in the field of ultrashort-focus laser projection display, in order to achieve better brightness and display effect, a projector can be matched with a projection screen with a Fresnel microstructure. The following illustrates a specific structure of the projection screen having the fresnel microstructure provided in the embodiment of the present application.

Referring to fig. 2, fig. 2 is a schematic structural diagram of a projection screen 1 according to an embodiment of the present disclosure. Projection screen 1 may include a reflective layer 11, a fresnel lens layer 12, and a functional layer 13. Fresnel lens layer 12 is provided in a layered manner with reflective layer 11, and functional layer 13 is provided in a layered manner on fresnel lens layer 12 on the side away from reflective layer 11.

As shown in fig. 3, fig. 3 is a schematic view of the structure inside the functional layer 13 shown in fig. 2. The projection screen may also include pigment particles 14 and modifying material 15. Pigment particles 14 may be distributed within at least one of fresnel lens layer 12 (fig. 2) and functional layer 13. As an example, the functional layer 13 shown in fig. 3 is distributed with pigment particles 14. Of course, pigment particles 14 may also be distributed in fresnel lens layer 12 of projection screen 1 shown in fig. 2.

With continued reference to fig. 3, the modifying material 15 is added to the materials of the functional layer 13 and the fresnel lens layer 12 (fig. 2) distributed with the pigment particles 14, i.e. the pigment particles 14 and the modifying material 15 are both located in the materials of the fresnel lens layer 12 (fig. 2) and the functional layer 13, and the modifying material 15 is only added to the structure distributed with the pigment particles 14.

The modifying material 15 may include at least one of a surfactant and a dispersant, and since the surfactant and the dispersant can reduce the tension of the fresnel lens layer 12 (fig. 2) and the base material of the functional layer 13 and increase the repulsive force between the pigment particles 14, the binding force between the pigment particles 14 and the fresnel lens layer 12 (fig. 2) and the base material of the functional layer 13 is strong, so that the pigment particles located in the fresnel lens layer 12 (fig. 2) and the functional layer 13 can maintain a dispersed state and are not easily agglomerated.

Based on this, as shown in fig. 2, the projection screen 1 provided in the embodiment of the present application includes a reflective layer 11, a fresnel lens layer 12, and a functional layer 13, which are stacked. When reaching the projection screen 1, the light rays projected by the projector 2 pass through the functional layer 13 and the fresnel lens layer 12 in sequence and then reach the reflective layer 11. Under the reflection of the reflective layer 11, the light is reflected to the fresnel lens layer 12 and the functional layer 13 in sequence, and finally reflected to the eyes of the viewer 3, so that the viewer 3 can view an image on the projection screen 1.

In addition, as shown in fig. 3, the projection screen provided in the embodiment of the present application further includes pigment particles 14 and a modifying material 15, and the pigment particles 14 and the modifying material 15 may be distributed in at least one of the fresnel lens layer 12 (fig. 2) and the functional layer 13 in the projection screen. Since the modifying material 15 includes at least one of a surfactant and a dispersant, it is possible to reduce the tension of the fresnel lens layer 12 (fig. 2) and the base material of the functional layer 13 and to increase the repulsive force between the pigment particles 14, so that the bonding force between the pigment particles 14 and the base material of the fresnel lens layer 12 and the functional layer 13 becomes large, and thus the pigment particles 14 located in the fresnel lens layer 12 and the functional layer 13 can be maintained in a dispersed state and are not easily agglomerated. Therefore, the projection screen provided by the embodiment of the application can enable the pigment particles 14 to be well dispersed in at least one of the functional layer 13 and the fresnel lens layer 12 (fig. 2), agglomeration is not easy to occur, the pigment particles 14 are not easy to migrate to the surface of the projection screen, the projection effect of the projection screen and the appearance quality of the projection screen are ensured, and the viewing experience of a user is improved.

Referring to fig. 2, since the light converges toward the center of the screen when passing through the fresnel lens layer 12, the viewer 3 can view an image with higher brightness at a position facing the projection screen 1, and the gain of the projection screen 1 is higher. Meanwhile, the fresnel lens layer 12 can also play a certain role in resisting ambient light, and the ambient light can be reflected towards a non-human eye viewing area under the action of the fresnel microstructure.

Referring to fig. 2, in some embodiments, the material of the functional layer 13 and the fresnel lens layer 12 on which the pigment particles 14 (fig. 3) are distributed may include an ultra violet ray (UV), i.e., the base material of the fresnel lens layer 12 and the functional layer 13 may be a UV glue and is made of a UV glue material. The UV glue is a high polymer material which is formed by polymerizing acrylic esters serving as a monomer under the action of an initiator through photo-initiation, and the UV glue can be bent due to the elasticity of the UV glue, so that the functional layer 13 and the Fresnel lens layer 12 can be bent, and the projection screen 1 can be curled.

As shown in fig. 4, fig. 4 is a schematic structural diagram of another functional layer 13 provided in the embodiment of the present application. In some embodiments, when the modifying material 15 includes the surfactant 151, i.e., the pigment particles 14 are added to the functional layer 13 or the fresnel lens layer 12 (fig. 2) simultaneously with the surfactant 151, the surfactant 151 may include an ionic surfactant for charging the surface of the pigment particles 14 to make the pigment particles repel each other.

As shown in fig. 4, due to the action of the ionic surfactant (surfactant 151 in fig. 4), the surfaces of the pigment particles 14 have the same charges, and due to mutual repulsion between the same charges, the pigment particles 14 are far away from each other under the repulsion force of the charges and do not approach and agglomerate, so that the pigment particles 14 can be kept dispersed in the base material of the functional layer 13, and agglomeration does not occur, thereby ensuring that the pigment particles 14 do not migrate to the surface of the screen to form black spots, and ensuring the projection effect of the projection screen. Of course, other types of surfactants may be selected to enhance the bonding force between the base material and the pigment particles 14 and to maintain the pigment particles 14 in a dispersed state in the base material without agglomeration.

In some embodiments, the ionic surfactant may include one of a fatty amine and a quaternary ammonium salt. The quaternary ammonium salt may be a quaternary ammonium salt, and when the ionic surfactant includes a fatty amine, the quaternary ammonium salt may be an ammonium salt of the fatty amine and a carboxylic acid. The materials can be well mixed in the substrate material, and the surface of the pigment particles is charged, so that the pigment particles are prevented from agglomerating.

As shown in fig. 3, when the modifying material 15 includes the dispersing agent 152, that is, when the pigment particles 14 and the dispersing agent 152 are added to the functional layer 13 or the fresnel lens layer 12 (fig. 2) at the same time, the dispersing agent 152 may include an inorganic dispersing agent. One end of the inorganic dispersant is adsorbed on the surface of the material particles 14, and the other end is dissolved in the material of the functional layer 13 and the fresnel lens layer 12 (fig. 2) on which the pigment particles 14 are distributed.

As shown in fig. 3, one end of the inorganic dispersant is adsorbed on the surface of the pigment particles 14, and the other end is dissolved in the material of the functional layer 13 on which the pigment particles 14 are distributed. That is, an adsorption layer is formed on the surface of the pigment particles 14, and the formed adsorption layer has a certain thickness. It can be known that the formed adsorption layers repel each other, so that the pigment particles 14 repel each other, are not easily agglomerated together, and can be well dispersed in the material of the functional layer 13.

It is understood that when the pigment particles 14 are directly distributed in the material of the functional layer 13 without the inorganic dispersant, an adsorption layer is also formed on the surface of the pigment particles, but the thickness of the adsorption layer is too thin, and the repulsive force between the adsorption layers is insufficient, so that the pigment particles 14 are easily agglomerated against the repulsive force between the adsorption layers when the surface energy is reduced. By adding the inorganic dispersant into the material of the functional layer 13, the inorganic dispersant is adsorbed on the surface of the pigment particles 14, and a thicker adsorption layer (the thickness can reach 8 nm-9 nm) can be formed, so that the repulsive force between the adsorption layers is larger, the repulsive force overcome when the pigment particles 14 are agglomerated is larger, and the agglomeration is more difficult. In addition, some polymer may be added to adsorb the polymer on the surface of the pigment particles 14 to form a thicker adsorption layer (thickness up to 50nm) so that the pigment particles can be better dispersed in the functional layer 13.

In some embodiments, the inorganic dispersant may include at least one of a polyphosphate and a hydroxyamine group. The inorganic dispersant may be sodium tripolyphosphate or an organic material having a hydroxyl amine group formed by reacting a branched hydroxyl group-containing organic material with a branched amine group, although the inorganic dispersant may be other polyphosphates and organic materials having a hydroxyl amine group.

When the inorganic dispersant is used, a thick adsorption layer can be formed on the surface of the pigment particles. Meanwhile, when the inorganic dispersant is adsorbed on the surfaces of the pigment particles, the surfaces of the pigment particles can be charged, so that repulsive force of charges exists among the pigment particles, the pigment particles 14 are further prevented from being agglomerated, and the pigment particles 14 are stably dispersed in the material of the functional layer 13.

It can be understood that, as shown in fig. 5, fig. 5 is a schematic structural diagram of another functional layer 13 provided in the embodiments of the present application. The modified material 15 may include both the dispersant 152 and the surfactant 151. In this way, an adsorption layer is formed on the surface of some of the pigment particles 14, and the surface of some of the pigment particles 14 has an electric charge.

In some embodiments, the mass ratio of pigment particles to modifying material may be 5: 1-10: 1. when the mass ratio of the two is within the above range, the improving agent can be sufficiently used for dispersing the pigment particles, and there is no remaining improving agent which does not exert an effect. If the proportion of the modifying material is too large, a part of the modifying material remains, and if the proportion of the modifying material is too small, the pigment particles may agglomerate. Illustratively, the mass ratio of pigment particles to modifying material may be 5: 1,7: 1,8: 1 or 10: 1.

based on the above ratio, in some embodiments, the mass ratio of the pigment particles in the fresnel lens layer and the functional layer may be 5% to 10%, that is, the pigment particles may account for 5% to 10% of the total mass of the fresnel lens layer or the functional layer. Illustratively, the mass proportion of the pigment particles may be 5%, 7% or 10%.

The pigment particles within the proportion range can better realize the effect of absorbing the ambient light, and simultaneously can reduce the loss of the pigment particles to the projection light of the projector as much as possible. If the proportion of the pigment particles is too high, the light projected by the projector is absorbed by the pigment particles more, thereby affecting the projection effect. If the proportion of the pigment particles is too low, the effect of absorbing ambient light cannot be effectively achieved, and the projection screen is less resistant to ambient light.

In addition, in order to improve other performances of the projection screen, the projection screen provided in the embodiment of the present application may further include other structures, and the projection screen with different structures provided in the embodiment of the present application is further described below with reference to the accompanying drawings.

As shown in fig. 2, to enlarge the viewing angle of the projection screen 1, in some embodiments, the projection screen 1 may further include a diffusion layer 16. The diffusion layer 16 may be located between the functional layer 13 and the fresnel lens layer 12. Diffusion particles 40 are distributed within the diffusion layer 16. Light entering the projection screen 1 passes through the diffusion layer 16 and is diffused in all directions by the diffusion particles 40.

The viewing angle of the projection screen 1 is increased due to the diffusion of the light. Meanwhile, the coherence of the diffused light rays is weak, so that the interference degree of the light rays on the surface of the projection screen 1 is reduced, and the severity of speckles appearing on the surface of the projection screen 1 is further weakened. The material of the diffusion particles 40 may be Polymethyl Methacrylate (PMMA).

Next, taking the projection screen shown in fig. 2 as an example, a process for manufacturing the functional layer 13 and the fresnel lens layer 12 will be described as an example.

Based on the projection screen 1 shown in fig. 2, the diffuser layer 16 may serve as a substrate for making the fresnel lens layer 12. Taking the example where the fresnel lens layer 12 is cured by UV glue, the UV glue allows the fresnel lens layer 12 to be curled because of its elasticity. When preparation fresnel lens layer 12, with the coating of UV glue on the surface of diffusion barrier 16, then impress fresnel lens layer 12 with dedicated mould for fresnel lens layer 12 shaping, then reuse UV light source lamp solidifies UV glue, and the preparation on fresnel lens layer 12 can be accomplished in the drawing of patterns at last. Of course, in other embodiments, the Fresnel lens layer 12 may be made of a heat curable glue.

Similarly, the functional layer 13 may be fabricated by selecting the diffusion layer 16 as a base. And coating UV glue on the surface of the diffusion layer 16 far away from the Fresnel lens layer 12, and then curing the UV glue by using a UV light source lamp to complete the manufacture of the functional layer 13.

It can be understood that when the fresnel lens layer 12 and the functional layer 13 are distributed with the pigment particles 14 (fig. 3) and the modifying material 15 (fig. 3), in the manufacturing of the two structures, the UV glue is mixed with the pigment particles 14 (fig. 3) and the modifying material 15 (fig. 3), and then the coating and curing processes are performed to complete the manufacturing of the fresnel lens layer 12 and the functional layer 13.

With continued reference to fig. 2, in some embodiments, projection screen 1 may further include a surface layer 17, where surface layer 17 is located on a side of functional layer 13 away from fresnel lens layer 12 to protect projection screen 1. Illustratively, the surface layer 17 may also be made of UV glue, and when the surface layer 17 is manufactured, the UV glue is coated on the surface of the functional layer 13 on the side away from the fresnel lens layer 12, and then the UV glue is cured by a UV light source lamp, so that the surface layer 17 is manufactured. Of course, the surface layer may also be made of a hard material, for example, a methyl methacrylate-styrene copolymer (MS) material.

The surface layer of the projection screen may have different structures in order to perform different functions. Several different surface layers provided by embodiments of the present application are exemplified below with reference to the accompanying drawings.

As shown in fig. 6, fig. 6 is a schematic structural diagram of another projection screen 1 provided in the embodiment of the present application. In some embodiments, the surface of the surface layer 17 on the side facing away from the functional layer 13 may be a Matte (Matte) surface, which has a low light reflectivity. Therefore, when the light projected by the projector 2 reaches the surface, more light can enter the projection screen 1 through the surface, so that the light projected by the projector 2 is not easy to form a clear image at other places (such as a ceiling), and the viewing experience of the audience 3 is ensured. The surface of the surface layer 17 far from the functional layer 13 can be treated by a sand blasting process to form an atomized surface, so that the operation is simple and convenient, and the realization is easy.

As shown in fig. 7, fig. 7 is a schematic structural diagram of a surface layer 17 according to an embodiment of the present application. In some embodiments, to further enlarge the viewing angle of the projection screen 1, the surface of the surface layer 17 on the side (left side) away from the functional layer may be distributed with diffusing particles 40. Through adding diffusion particle 40 on this surface, can increase projection screen's the visual angle of watching, also can increase the roughness on this surface simultaneously for more this surface of seeing through of light is difficult to form clear image elsewhere, promotes spectator's viewing experience.

As shown in fig. 8, fig. 8 is a schematic structural diagram of another surface layer 17 provided in the embodiments of the present application. In some embodiments, the surface of the surface layer 17 on the side (left side) away from the functional layer is distributed with microlenses (Lenti) 50. By providing the microlenses 50, the viewing angle of the projection screen can be increased as well, while reducing the surface reflectivity. Wherein the shape of the microlens 50 may be a hemisphere.

Referring to fig. 9, fig. 9 is a schematic structural view of the microlens 50 of the surface layer 17 shown in fig. 8 after being subjected to the atomization treatment. In some embodiments, the surface of the microlens 50 may be a fogging surface. Carry out atomization process through the surface to microlens 50, can further improve the roughness on this surface, and then make light further reduce at the reflectivity on this surface to make the transmissivity of light higher, and then improve the utilization efficiency of the light that the projector throws, reduce because of the probability that light reflection formed clear image elsewhere.

In some embodiments, as shown in fig. 10, fig. 10 is a schematic structural diagram of another projection screen 1 provided in the embodiments of the present application. Projection screen 1 may also include a substrate layer 18, and substrate layer 18 may be located between surface layer 17 and reflective layer 11. The substrate layer 18 may serve as a support base for the projection screen 1. Taking the projection screen 1 shown in fig. 10 as an example, the base layer 18 serves as a base for producing the surface layer 17, the functional layer 13, and the fresnel lens layer 12. When the surface layer 17 is manufactured, the UV glue is coated on the surface of one side, away from the Fresnel lens layer 12, of the base material layer 18, and then the UV glue is cured by using a UV light source lamp, so that the surface layer 17 can be manufactured.

The substrate layer 18 may be made of different materials. For example, the substrate layer 18 may be made of a Polyethylene terephthalate (PET) material. The PET material is flexible, which in turn allows the substrate layer 18 to be flexible and capable of being rolled. Of course, the substrate layer 18 may be made of other flexible materials, for example, the substrate layer 18 may be made of Thermoplastic polyurethane elastomer (TPU) material, and the TPU has elasticity and can achieve curling. Alternatively, the substrate layer 18 may also be made of Styrene Block Copolymers (SBC) flexible materials. For another example, the substrate layer 18 may be made of an MS material.

The MS material has high hardness, cannot be curled and has good flatness, so that the projection screen has good flatness. The TPU has wide hardness range, can still keep good elasticity and wear resistance when the hardness is increased, has good oil resistance, aging resistance and wear resistance, and has lower cost. The SBC material has good flexibility, good mechanical property, waterproofness, and stronger tensile strength, tear strength and ball bursting strength than the MS material. Has better oxidation resistance, water resistance, weather resistance, chemical resistance and corrosion resistance. The material has a rough lower surface, is in a three-dimensional net structure, can have good bonding strength with various adhesives, and can be blended with other materials to improve the performance and strength of the material.

For example, the base layer 18 may be made of Polyurethane (PU), Polyethylene (PE), Polyvinyl chloride (PVC), or polypropylene (PP). The PU material can adapt to the adhesion of base materials with different thermal expansion coefficients, a soft-hard transition layer can be formed between the PU material and the base materials, and the adhesion force is strong. Thus, it has better bonding with other layered structures of the projection screen. And has excellent buffering and shock-absorbing functions.

The PE material is odorless, nontoxic, wax-like in hand feeling, excellent in low-temperature resistance, good in chemical stability and capable of resisting corrosion of most of acid and alkali. Is insoluble in common solvents at room temperature, has low water absorption and excellent circuit insulation.

The PVC material has good size stability, good weather resistance and lower cost. Meanwhile, the PVC material can adjust the hardness by using a plasticizer. The PP material is easy to dye, light in texture, good in toughness, good in temperature resistance and chemical resistance.

As shown in fig. 10, in some embodiments, the number of substrate layers 18 may be plural. The projection screen 1 shown in fig. 10 is provided with two base material layers 18. One of the substrate layers 18 is located between the surface layer 17 and the functional layer 13, and can be used as a base for manufacturing the surface layer 17 and the functional layer 13. Another substrate layer 18 is located between the functional layer 13 and the fresnel lens layer 12, and can be used as a base for manufacturing the functional layer 13 and the fresnel lens layer 12.

With continued reference to fig. 10, the projection screen 1 may further include an adhesive layer 19, the adhesive layer 19 being positioned between the substrate layer 18 and the functional layer 13. The functional layer 13 and the base material layer 18 may be bonded by an adhesive layer 19. Illustratively, the adhesive layer 19 may be an optically clear adhesive. Of course, in other embodiments, the projection screen 1 may not be provided with the adhesive layer 19, and the functional layer 13 may be directly formed using one of the substrate layers 18 as a base, as described above. Thus, the adhesive layer 19 is not required to be provided for bonding.

In some embodiments, referring to fig. 11, fig. 11 is a schematic structural diagram of another projection screen 1 provided in the embodiments of the present application. The projection screen 1 shown in fig. 11 is provided with a base material layer 18. The surface of the substrate layer 18 on the side away from the surface layer 17 is provided with light-transmitting protrusions 181. When the light passes through the light-transmitting protrusions 181, the light is diffused, thereby increasing the viewing angle of the projection screen 1. Meanwhile, since the light is diffused, coherence between the light is reduced, so that the severity of speckle formed on the projection screen 1 is reduced. The transparent protrusion 181 may be a cylindrical lens, and referring to fig. 9, a cross section of the transparent protrusion 181 along a plane perpendicular to an extending direction thereof may be a semi-circle, that is, the transparent protrusion 181 is a semi-cylindrical shape.

In some embodiments, referring to fig. 12, fig. 12 is a schematic structural diagram of another projection screen 1 according to an embodiment of the present disclosure. The substrate layer 18 of the projection screen 1 shown in fig. 12 is located on one side of the functional layer 13, and the two surfaces of the substrate layer 18 and the functional layer 13 close to each other are both provided with light-transmitting protrusions 181. Similarly, the shape of the light-transmitting protrusion 181 may be a semi-cylindrical shape. Illustratively, the extending directions of the substrate layer 18 and the light-transmitting protrusions 181 on the surface of the functional layer 13 may be perpendicular to each other.

Typically, projection screens are generally rectangular. Referring to fig. 12, the up-down direction in fig. 12 is the width direction of the projection screen 1, and the width direction is the vertical direction viewed by the viewer 3. The direction perpendicular to the plane shown in fig. 12 is the lengthwise direction of the projection screen 1, i.e., the horizontal direction viewed by the viewer. Thereby, the light-transmitting protrusions 181 of the base layer 18 extend in the longitudinal direction of the projection screen 1. Thus, when the light passes through the light-transmitting protrusion 181, the light is diffused along the width direction of the projection screen 1, thereby increasing the viewing angle of the projection screen 1 in the vertical direction. The light-transmitting protrusions 181 on the surface of the functional layer 13 extend in the width direction of the projection screen 1. Thus, light rays passing through the light-transmitting protrusions 181 are diffused along the length direction of the projection screen 1, thereby increasing the viewing angle of the projection screen 1 in the horizontal direction.

In addition, the fresnel lens layer in the projection screen provided in the embodiment of the present application may also have different structures. Several different fresnel lens layer configurations are illustrated in the following figures.

In some embodiments, referring to fig. 13, fig. 13 is a schematic structural diagram of a fresnel lens layer 12 according to an embodiment of the present disclosure. Diffusing particles 40 are distributed within fresnel lens layer 12. By distributing the diffusing particles 40 in the fresnel lens layer 12 to enlarge the viewing angle, the thickness of the projection screen can be reduced without providing a separate diffusing structure.

In some embodiments, referring to fig. 14, fig. 14 is a schematic structural diagram of another fresnel lens layer 12 provided in the embodiments of the present disclosure. The surface of the fresnel lens layer 12 on the side where the fresnel microstructure is provided with microlenses 50. By providing the microlens 50, light can be diffused, so that the viewing angle of the projection screen becomes large. Meanwhile, coherence among the diffused light rays is reduced, and further the severity of speckles formed on the projection screen can be reduced.

As can be seen from the above, the reflective layer can reflect light. The reflective material in the reflective layer may also be aluminum, silver, or a combination of silver and aluminum in order to achieve the reflective function of the reflective layer. For better reflection of light, different shapes of materials can be chosen as the material of the reflective layer. In the following, taking the example of selecting aluminum as the reflective material, several different reflective layers provided in the embodiments of the present application will be exemplarily described with reference to the drawings.

In some embodiments, as shown in fig. 15, fig. 15 is a schematic structural diagram of a reflective layer 11 provided in the embodiments of the present application, and in order to improve the gain of the projection screen 1, powdered aluminum powder may be selected and coated on the fresnel lens layer 12 by using a spray printing or evaporation method. Therefore, because the powdered aluminum powder is finer and more delicate and has insignificant directivity, most of the light emitted by the projector can be reflected out of the projection screen directionally according to the arrangement of the microstructure of the fresnel lens layer 12, and the light cannot be reflected around randomly, so that the gain of the projection screen is higher.

Further, when aluminum particles are selected as the reflective material, the diameter of the aluminum particles may range from 5um to 20 um. The aluminum particles in the range have small diameters, so that after the reflective layer 11 is formed, the aluminum particles can form a compact reflective surface, and when light irradiates on the reflective surface, the light can be reflected as much as possible, so that the waste of light energy is avoided. Meanwhile, when the aluminum particles are selected as the reflective material, the reflective layer 11 can be made very thin, so that the consumption of the aluminum material can be reduced, and the manufacturing cost can be saved.

In other embodiments, as shown in fig. 16, fig. 16 is a schematic structural diagram of another reflective layer 11 provided in the embodiments of the present application. When the reflective material of the reflective layer 11 is aluminum, a scaly aluminum powder may be selected. The scale-shaped aluminum powder is sprayed on the fresnel lens layer 12 by means of spray printing. The scaly aluminum powder has larger diameter-thickness ratio, so the bonding capability of aluminum is stronger and the aluminum is not easy to fall off. Wherein the diameter-thickness ratio of the scale-like aluminum powder can range from (40:1) to (100: 1).

An embodiment of the present application further provides a method for manufacturing any one of the projection screens described above, as shown in fig. 17, fig. 17 is a first flowchart illustrating a manufacturing method of a projection screen provided in the embodiment of the present application, and the manufacturing method may include steps S100 to S200.

S100: and mixing the improved material with the base material to obtain the mixed material.

It can be understood that the base material refers to a material for manufacturing the fresnel lens layer and the functional layer, and when manufacturing, the improved material is mixed with the base material to obtain a mixed material, and the mixed material can be used for manufacturing the subsequent fresnel lens layer and the functional layer.

S200: pigment particles are added to the mixed material.

After the mixed material is obtained, the pigment particles are added into the mixed material, and the improved material is added into the mixed material, so that the pigment particles can be well dispersed in the mixed material, and the pigment particles are not easy to agglomerate subsequently.

When the hybrid material is used to fabricate the fresnel lens layer, as shown in fig. 17, the method further includes S300 to S400.

S300: a fresnel lens layer made of a mixed material to which pigment particles are added is formed on the functional layer side.

Taking the projection screen 1 shown in fig. 2 as an example, the diffusion layer 16 is used as a substrate, and the mixed material is coated on the surface of the diffusion layer 16 far from the functional layer 13, so as to form the fresnel lens layer 12.

S400: and forming a reflecting layer on one side of the Fresnel lens layer far away from the functional layer.

Taking the projection screen 1 shown in fig. 2 as an example, when the reflection layer 11 is produced, the fresnel lens layer 12 is used as a production substrate, and the reflection layer 11 is formed on one side of the fresnel lens layer 12 so as to be laminated on the fresnel lens layer 12. The material of the reflective layer 11 may be metal aluminum, and for example, aluminum powder is sprayed on the fresnel lens layer 12 by means of spray printing. Thus, the reflective layer 11 is completed.

When the mixed material is used to fabricate the functional layer, as shown in fig. 18, fig. 18 is a second flowchart of the fabrication method of the projection screen provided in the embodiment of the present application, and the fabrication method may include S500 to S600.

S500: a functional layer made of a mixed material to which pigment particles are added is formed on the Fresnel lens layer side.

S600: and forming a reflecting layer on one side of the Fresnel lens layer far away from the functional layer.

In some embodiments, when the substrate material is a shadowless adhesive, as shown in fig. 19, fig. 19 is a third flowchart of a manufacturing method of a projection screen provided in the embodiment of the present application, and forming a fresnel lens layer made of a mixed material added with pigment particles on one side of the functional layer may include steps S310 to S330.

S310: one side of the functional layer is coated with a shadowless glue mixed with pigment particles and an improved material.

S320: and (4) impressing the shadowless adhesive by using a mold to obtain the shadowless adhesive layer with the Fresnel microstructure.

S330: and curing the shadowless adhesive layer by using a UV light source lamp to obtain the Fresnel lens layer.

For example, taking the projection screen shown in fig. 2 as an example, the surface of the diffusion layer 16 away from the functional layer 13 is coated with the above-mentioned shadowless glue, and then a mold is used to perform imprinting to obtain a shadowless glue layer with a microstructure, and then the shadowless glue is cured by using a UV light source lamp.

When the base material is a shadowless adhesive, as shown in fig. 20, fig. 20 is a fourth flowchart of the method for manufacturing a projection screen according to the embodiment of the present application, and the step of forming the functional layer made of a mixed material added with pigment particles on one side of the fresnel lens layer may include steps S510 to S520.

S510: and coating a shadowless adhesive mixed with pigment particles and an improved material on one side of the Fresnel lens layer, which is far away from the reflecting layer.

S520: and (5) curing the shadowless glue by using a UV light source lamp to obtain the functional layer.

For example, taking the projection screen shown in fig. 2 as an example, the surface of the diffusion layer 16 on the side away from the fresnel lens layer 12 is coated with the above-mentioned shadowless adhesive, and then the shadowless adhesive is cured by using a UV light source lamp.

The above description is only for the specific embodiments of the present application, but the scope of the present application is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present application should be covered within the scope of the present application. Therefore, the protection scope of the present application shall be subject to the protection scope of the claims.

Claims

1. A projection screen, comprising:

a reflective layer;

a Fresnel lens layer stacked on the reflective layer;

the functional layer is arranged on one side, far away from the reflecting layer, of the Fresnel lens layer in a laminated mode;

pigment particles distributed in at least one of the Fresnel lens layer and the functional layer; and the number of the first and second groups,

the improved material is added into the materials of the functional layer and the Fresnel lens layer distributed with the pigment particles; the modifying material includes at least one of a surfactant and a dispersant.

2. The projection screen of claim 1 wherein the material of the functional layer and the fresnel lens layer on which the pigment particles are distributed comprises a shadowless glue.

3. The projection screen of claim 2 wherein the surfactant comprises:

an ionic surfactant for charging surfaces of the pigment particles to repel each other.

4. The projection screen of claim 3 wherein the ionic surfactant comprises at least one of a fatty amine and a quaternary ammonium salt.

5. The projection screen of claim 1 wherein the dispersant comprises:

one end of the inorganic dispersant is adsorbed on the surface of the pigment particles, and the other end of the inorganic dispersant is dissolved in the materials of the functional layer and the Fresnel lens layer distributed with the pigment particles.

6. The projection screen of claim 5 wherein the inorganic dispersant comprises at least one of a polyphosphate and a hydroxyl amine group.

7. The projection screen of claim 1 wherein the mass ratio of the pigment particles to the modifying material is 5: 1-10: 1.

8. the projection screen of claim 7 wherein the pigment particles are present in the fresnel lens layer and the functional layer at a mass fraction of 5% to 10%.

9. A method for making the projection screen of any of claims 1-8, the method comprising:

mixing the improved material with a base material to obtain a mixed material;

adding the pigment particles to the mixed material;

the method comprises the following steps:

forming the fresnel lens layer made of a mixed material to which the pigment particles are added on the functional layer side;

forming the reflecting layer on one side of the Fresnel lens layer far away from the functional layer; or the like, or, alternatively,

the method comprises the following steps:

forming the functional layer made of a mixed material to which the pigment particles are added on one side of the fresnel lens layer;

and forming the reflecting layer on one side of the Fresnel lens layer far away from the functional layer.

10. The method of claim 9, wherein the base material is a shadowless glue; the forming of the fresnel lens layer made of a mixed material added with pigment particles on the functional layer side includes:

coating the shadowless glue mixed with the pigment particles and the improved material on one side of the functional layer;

impressing the shadowless adhesive by using a mold to obtain a shadowless adhesive layer with a Fresnel microstructure;

curing the shadowless adhesive layer by using a UV light source lamp to obtain the Fresnel lens layer;

the forming of the functional layer made of a mixed material added with pigment particles on the fresnel lens layer side includes:

coating the shadowless glue mixed with the pigment particles and the improved material on one side of the Fresnel lens layer away from the reflecting layer;

and curing the shadowless glue by using a UV light source lamp to obtain the functional layer.