CN115202144A - Projection screen and manufacturing method thereof - Google Patents
Projection screen and manufacturing method thereof Download PDFInfo
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- CN115202144A CN115202144A CN202211115532.0A CN202211115532A CN115202144A CN 115202144 A CN115202144 A CN 115202144A CN 202211115532 A CN202211115532 A CN 202211115532A CN 115202144 A CN115202144 A CN 115202144A
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- lens
- roller
- projection screen
- base material
- material film
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03B—APPARATUS OR ARRANGEMENTS FOR TAKING PHOTOGRAPHS OR FOR PROJECTING OR VIEWING THEM; APPARATUS OR ARRANGEMENTS EMPLOYING ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ACCESSORIES THEREFOR
- G03B21/00—Projectors or projection-type viewers; Accessories therefor
- G03B21/54—Accessories
- G03B21/56—Projection screens
- G03B21/60—Projection screens characterised by the nature of the surface
- G03B21/602—Lenticular screens
Abstract
A projection screen and a manufacturing method thereof are provided, the screen comprises an optical structure functional layer, the optical structure functional layer comprises a first optical structure and a second optical structure, the first optical structure is used for reflecting projection light along the left side and the right side of the projection screen, and the second optical structure is used for reflecting the projection light along the upper side and the lower side of the projection screen. The projection screen changes the direction of the projection light by arranging the vertical first optical structure and the transverse second optical structure, so that the projection light can be reflected to the left side, the right side, the upper side and the lower side of the projection screen, the distribution of the projection light is more uniform, and the display brightness of a projection picture viewed in any direction is basically consistent. In addition, the first optical structures and the second optical structures are distributed at intervals to form a structure with alternate concave and convex parts, and air between the die roller and a material is exhausted during processing, so that the processing yield of products can be improved. The projection screen has uniform brightness, easy processing and strong practicability.
Description
Technical Field
The present invention relates to a projection screen, and more particularly, to a projection screen with uniform brightness and increased viewing angle and a method for manufacturing the same.
Background
Projection screens are generally classified into front projection screens and rear projection screens. Among them, the front projection screen generally relies on the reflection principle, and the rear projection screen relies on the transmission principle. The existing front projection type projection screen is mainly used for directly processing an imaging layer on the surface of a base material to be used for projecting light reflection, and due to the structure, the light reflection is large, the mirror reflection is easy to form, the screen brightness is low, the visual angle is small, the problem of uneven viewing brightness is easy to occur, namely, the problem that people see which area of a picture is bright at which position of the screen is easy to occur.
Disclosure of Invention
The present invention is directed to solving the above-mentioned problems, and provides a projection screen with more uniform brightness and larger viewing angle and a method for manufacturing the same.
In order to solve the above problems, the present invention provides a projection screen, which includes an optical structure functional layer, where the optical structure functional layer includes a first optical structure and a second optical structure, the first optical structure is used to reflect projection light along the left and right sides of the projection screen, and the second optical structure is used to reflect projection light along the upper and lower sides of the projection screen.
Furthermore, the first optical structure comprises a plurality of first lens parts and a first reflection part, wherein the first lens parts extend from one end of the projection screen to the other end along the vertical direction, and the first reflection part is arranged on the first lens parts and can reflect light; the second optical structure comprises a plurality of second lens parts and second reflecting parts, and the second reflecting parts are arranged on the second lens parts and can reflect light; the projection screen is provided with a plurality of second lens parts in the transverse direction and the vertical direction respectively; the first and second reflection parts are connected to each other to form a reflection layer covering all of one side surfaces of the first and second lens parts.
Furthermore, the first lens parts are distributed in parallel at intervals, a plurality of second lens parts are arranged between every two adjacent first lens parts, and the distance between the second lens parts (121) positioned between every two adjacent first lens parts (111) is in a decreasing trend from bottom to top; the second lens part extends along the transverse direction, two ends of the second lens part are respectively connected with the first lens part, one side surfaces of the first lens part and the second lens part are connected to form a plane, and the other side surfaces of the first lens part and the second lens part are connected to form a structure with concave-convex intervals.
Further, the top of the second lens portion is lower than the top of the first lens portion.
Furthermore, the first lens part is a semi-cylindrical lens, and the first reflection part is arranged on the cylindrical surface of the semi-cylindrical lens; the second reflection part is arranged on the surface of the second lens part, which is positioned on the same side with the cylindrical surface.
Furthermore, a substrate layer is arranged on the surface of the optical structure functional layer opposite to the reflecting layer.
Further, a transparent protective layer is arranged on the surface of the reflecting layer opposite to the first lens part.
In addition, the invention also provides a manufacturing method of the projection screen, which is characterized by comprising the following steps:
s1, selecting or manufacturing a die roller: the outer wall of the circumference of the die roller is continuously provided with a reverse texture structure matched with the first lens part and the second lens part;
s2: arranging the die roller and the compression roller in parallel at intervals, wherein the die roller can continuously rotate;
s3, passing the base material film through the space between the die roller and the press roller, and leading the base material film to wind the die roller and be led out from the other side of the die roller; transferring the reverse texture structure to the base material film by extrusion of a die roller and a press roller to process the first lens part and the second lens part;
and S4, spraying a reflective imaging material on one side of the base material film on which the first lens part and the second lens part are formed to form a reflective layer.
Further, step S3 specifically includes:
s311, heating the base material film; introducing cooling liquid into the die roller;
s312, the heated base material film passes through the space between the cooled die roller and the compression roller, and the reverse texture structure is transferred to the base material film through the extrusion of the die roller and the compression roller;
s313, winding the base material film on a cooled mold roller, and forming the transferred inverse grain structure through the cooled mold roller to process the first lens part and the second lens part;
and S314, leading the base material film out of the other side of the cooled die roller, and demoulding the base material film and the die roller through the low temperature of the die roller.
Further, step S3 specifically includes:
s321, passing the base material film through the space between the die roller and the press roller, and leading the base material film to wind on the die roller and be led out from the other side of the die roller;
s322, supplying liquid UV glue between the base material film and the die roll, and enabling the liquid UV glue to enter between the reverse texture structure and the base material film through extrusion of a press roll and the die roll;
s323, carrying out UV irradiation on the base material film wound on the mold roller from the outer side of the mold roller, and curing and molding the liquid UV glue entering the reverse texture structure and the base material film so as to transfer the reverse texture structure to form the first lens part and the second lens part formed on the base material film.
Further, the base material film passes through between the die roller and the press roller by passing over the press roller; the liquid UV glue is fed into the space between the base material film and the die roller from the position above the position between the press roller and the die roller; and the two ends of the die roller and the compression roller are provided with glue blocking plates for preventing the liquid UV glue from flowing outwards.
The present invention advantageously contributes to effectively solving the above-mentioned problems. The projection screen changes the direction of projection light by arranging the first optical structure 11 which is vertically arranged and the second optical structure which is transversely arranged, so that the projection light can be reflected to the left side, the right side, the upper side and the lower side of the projection screen, the distribution of the projection light is more uniform, and the display brightness of a projection picture viewed in any direction is basically consistent. In addition, the structure of the projection screen is beneficial to processing and product yield, has strong practicability and is suitable for being widely popularized.
Drawings
Fig. 1 is a schematic structural view of an optical structure functional layer and a substrate layer.
Fig. 2 is a schematic plan view of the distribution of the first lens portion and the second lens portion.
Fig. 3 is a schematic plan view of the distribution of the first lens portion and the second lens portion.
Figure 4 is a schematic cross-sectional view of an optical structure functional layer.
Fig. 5 is a schematic cross-sectional view of a projection screen.
Fig. 6 is a schematic view of the processing principle.
FIG. 7 is a schematic view of the structure of the die cylinder.
Fig. 8 is a partially enlarged schematic view of the die cylinder.
The attached drawings are as follows: the structure comprises an optical structure functional layer 10, a first optical structure 11, a first lens portion 111, a second optical structure 12, a second lens portion 121, a reflecting layer 13, a substrate layer 20, a protective layer 30, an anti-glare layer 40, a mold roller 50, an anti-texture structure 51, a first anti-texture 511, a second anti-texture 512, a press roller 60, a substrate film 70, a containing cavity 80 and a UV lamp 90.
Detailed Description
The following examples are further illustrative and supplementary to the present invention and do not limit the present invention in any way.
As shown in fig. 1 to 5, the projection screen of the present invention includes an optical structure functional layer 10. Further, it may further include a substrate layer 20, a protective layer 30, and an antiglare layer 40.
As shown in fig. 1, the optical structure functional layer 10 may reflect and form an image, and may reflect the projection light along the left and right sides and the upper and lower sides of the projection screen, so as to prevent the projection light from only reflecting towards the upper and lower sides or the left and right sides of the projection screen, so that the projection light is more uniformly distributed, and the display brightness of the projection image viewed in any direction is substantially uniform.
As shown in fig. 1, the optical structure functional layer 10 includes a first optical structure 11 and a second optical structure 12. The first optical structure 11 may reflect the projection light along the left and right sides of the projection screen. The second optical structure 12 may reflect the projection light along the upper and lower sides of the projection screen.
The left side, the right side, the upper side and the lower side are relative to the position of the projection screen in normal use. The first optical structure 11 can reflect the projection light along the left and right sides of the projection screen, and it should be understood that the first optical structure 11 can mainly reflect the projection light toward the left and right sides of the projection screen, and is not limited to only reflect the projection light along the left and right sides of the projection screen. Similarly, the second optical structure 12 may reflect the projection light along the upper and lower sides of the projection screen, and it should be understood that the second optical structure 12 may mainly reflect the projection light towards the upper and lower sides of the projection screen, and is not limited to only reflect the projection light along the upper and lower sides of the projection screen.
Further, as shown in fig. 1, the first optical structure 11 includes a plurality of first lens portions 111 and a first reflection portion. The first lens part 111 is used for changing the transmission direction of the projection light, and the first reflection part is used for reflection imaging.
The single first lens part 111 extends vertically from one end of the projection screen to the other end; the plurality of first lens portions 111 are arranged in a lateral direction of the projection screen. The first lens portions 111 may have the same or different dimensions, and may be specifically provided as needed. In the present embodiment, the plurality of first lens portions 111 are uniform in size. The plurality of first lens portions 111 may be spaced apart from each other or may be connected to each other, and may be specifically provided as needed. In some embodiments, the plurality of first lens portions 111 may also be connected between some first lens portions 111, and some first lens portions 111 are spaced apart from each other. When the first lens portions 111 are spaced apart from each other, the distances may be equal or different, and may be specifically provided as needed. Further, when the first lens portions 111 are spaced apart from each other, they may be spaced apart in parallel or spaced apart in non-parallel. In this embodiment, the first lens portions 111 are spaced in parallel and are spaced at equal intervals, so as to form a uniform array distribution. The first lens portion 111 extends in a vertical direction as a whole, so that the projection light can be reflected with respect to the left and right sides of the projection screen.
The first reflection part is provided on one surface of the first lens part 111, and reflects light. In a specific implementation, the first reflective portion may be formed by coating a material with high reflectivity on the surface of the first lens portion 111. The thickness of the first reflection portion may be set as needed. In some embodiments, the first reflection part may be thinly coated on the first lens part 111 such that the shape of the first reflection part conforms to the surface shape of the first lens part 111. In some embodiments, the first reflection portion may be thickly coated on the first lens portion 111 such that a side surface of the first reflection portion facing away from the first lens portion 111 is relatively flush.
In this embodiment, as shown in fig. 1, the first lens portion 111 is a semi-cylindrical lens, and the first reflective portion is disposed on a cylindrical surface of the semi-cylindrical lens. The radius range value of the semi-cylindrical lens is 10-500 microns, and the cylindrical surface height of the semi-cylindrical lens is 20-80% of the radius range value, for example: the radius range value of the cylindrical lens is 50 microns, and the height of the cylindrical surface of the cylindrical lens is 10-40 microns; the semi-cylindrical lenses are spaced in parallel, the spacing distance between the circle centers of the semi-cylindrical lenses is 2.01 to 3 times of the radius range value, if the radius of the semi-cylindrical lenses is 50 micrometers, the spacing distance between the circle centers of the semi-cylindrical lenses is 100.5 to 150 micrometers.
As shown in fig. 1, the second optical structure 12 includes a plurality of second lens portions 121 and a second reflection portion. The second lens part 121 is used to change the transmission direction of the projection light, and the second reflection part is used to reflect and form an image.
The single second lens portion 121 extends in a lateral direction of the projection screen so that it allows the second optical structure 12 to reflect the projection light toward upper and lower sides of the projection screen. In the present embodiment, a plurality of second lens portions 121 are provided in both the horizontal and vertical directions of the projection screen, respectively.
Further, as shown in fig. 1, the second lens portions 121 are distributed between two adjacent first lens portions 111, and two ends of the second lens portions along the transverse direction are respectively connected to the first lens portions 111. The second lens portion 121 is connected to one surface of the first lens portion 111 in a planar shape, and the other surface is connected to the other surface in a concave-convex alternating manner.
Further, as shown in fig. 1, a plurality of second lens portions 121 are provided between two adjacent first lens portions 111. The plurality of second lens portions 121 located in the same column may be connected to each other or spaced from each other, and may be specifically disposed as needed. In this embodiment, the second lens portions 121 located in the same row are spaced from each other, and the distance between the second lens portions 121 decreases from bottom to top; in other words, the distance between the second lens portions 121 in the same column positioned at the lower portion of the projection screen is larger, and the distance between the second lens portions 121 in the same column positioned at the upper portion of the projection screen is smaller. By setting the distance between the second lens portions 121 in the same column to a structure decreasing from bottom to top, the projection light emitted by the short-focus projection device can be better reflected to the middle area of the field of view, and the brightness of the projection screen during viewing is more uniform.
Further, the plurality of second lens portions 121 distributed along the lateral direction of the projection screen may be located on the same straight line (as shown in fig. 3) or may not be located on the same straight line (as shown in fig. 2), and may be specifically disposed as needed.
In some embodiments, as shown in fig. 2, the plurality of second lens portions 121 are distributed in concentric circular arcs, that is, the second lens portions 121 adjacent in the transverse direction are on the same circular arc line, and the second lens portions 121 adjacent in the vertical direction are on circular arc lines of different diameters concentrically arranged.
The second lens portions 121 may be identical or different in shape and size, and may be specifically provided as needed. When the plurality of second lens portions 121 distributed laterally along the projection screen are located on the same straight line, the second lens portions 121 are preferably the same size and the same shape.
The surface of the second lens portion 121 for functioning may be a flat surface or a curved surface, and may be one surface or a plurality of surfaces. The second lens portion 121 may be formed in any shape as needed.
In some embodiments, as shown in fig. 1 and 4, the second lens portion 121 is a cylindrical structure with a triangular cross section, and the axial direction thereof extends along the transverse direction of the projection screen, and both ends thereof along the transverse direction are respectively connected to the first lens portion 111. The second lens portion 121 of this structure has two planar surfaces that can function.
In some embodiments, the second lens portion 121 has a cross-sectional trapezoidal column structure, and the axial direction thereof extends along the transverse direction of the projection screen, and both ends thereof along the transverse direction are respectively connected to the first lens portion 111. The second lens portion 121 of this structure has three planar surfaces that can function.
In some embodiments, the second lens portion 121 is a cylindrical structure with a semicircular cross section, and the axial direction thereof extends along the transverse direction of the projection screen, and both ends thereof along the transverse direction are respectively connected with the first lens portion 111. In the second lens portion 121 having this structure, a cylindrical surface (curved surface) extending in the lateral direction is a surface for functioning.
For convenience of processing, as shown in fig. 1 and 4, the top of the second lens portion 121 is lower than the top of the first lens portion 111. Thus, when the cylindrical mold roller 50 is provided with the inverse texture structures 51 matched with the first lens parts 111 and the second lens parts 121, the inverse texture structures 51 are of a structure with alternate concave and convex, the first inverse textures 511 matched with the first lens parts 111 are communicated through the second inverse textures 512 matched with the second lens parts 121, and when the optical structure functional layer 10 is subjected to transfer printing processing by using the inverse texture structures 51, the second inverse textures 512 communicated through the inverse texture structures 51 of the first inverse textures 511 can facilitate air discharge in the rotating and extruding process of the mold roller 50, so that the phenomenon of 'air inclusion' is avoided, and the yield of products is improved.
The second reflection part is provided on one side surface of the second lens part 121, and reflects light. In a specific implementation, the second reflective portion may be formed by disposing a material with strong reflectivity on the surface of the second lens portion 121. The thickness of the second reflecting portion may be set as required. In some embodiments, the second reflective portion may be thinly coated on the second lens portion 121 such that the shape of the second reflective portion conforms to the surface shape of the second lens portion 121. In some embodiments, the second reflection portion may be coated on the second lens portion 121 in a thick manner so that a side surface of the second reflection portion facing away from the first lens portion 111 is relatively flush.
Further, the first and second reflection portions are located on the same side surface of the first and second lens portions 111 and 121, and the first and second reflection portions are adjacent to each other to form a reflection layer 13 covering all of the first and second lens portions 111 and 121 on one side surface.
Thus, the optical structure functional layer 10 is formed, the first lens portion 111 and the second lens portion 121 are provided at an interval to change the light transmission direction, and the first reflection portion and the second reflection portion are provided on the first lens portion 111 and the second lens portion 121, respectively, to reflect light.
Further, as shown in fig. 5, a substrate layer 20 is disposed on the side of the optical structure functional layer 10 opposite to the reflective layer 13. The substrate layer 20 is a structure for carrying the optical structure functional layer 10 during processing.
In some embodiments, the substrate layer 20 is made of a transparent material, and both side surfaces of the projection screen can be used as the imaging surfaces. In other words, the projection apparatus may be placed in front of the reflective layer 13 or in front of the base layer 20.
In some embodiments, the substrate layer 20 may be made of a non-transparent material, in which case, the projection apparatus may be placed in front of the reflective layer 13 for front projection, and the substrate layer 20 may be used to block ambient light at the back side of the projection screen, so as to prevent the ambient light from interfering with the projection light, thereby improving the contrast of the projection image.
The substrate layer 20 and the first lens section 111 and the second lens section 121 in the optical structure functional layer 10 may be integrally molded or may be a composite layer structure, and may be specifically provided as needed.
The material for making the substrate layer 20 may be selected according to the requirement, and includes but is not limited to PET, PVC, TPU, PMMA, and the like.
Further, as shown in fig. 5, a protective layer 30 is provided on the surface of the reflective layer 13. The protective layer 30 is used to protect the reflective layer 13 and prevent the reflective layer 13 from falling off or being worn. The protection layer 30 is a transparent layer, which is transparent to light. The protective layer 30 may be an ink layer or a film layer, and may be specifically disposed as needed. In the present embodiment, the surface gloss of the protective layer 30 is less than 20 °, and the thickness thereof is less than 10 μm.
Further, as shown in fig. 5, an antiglare layer 40 may be disposed on the surface of the substrate layer 20, and the surface of the antiglare layer 40 is frosted, and the surface gloss is less than 20 degrees, which may reduce glare effect.
When the projection light emitted by the projection device enters the optical structure functional layer 10, part of the light is reflected by the first reflection portion and emitted towards the left and right sides of the projection screen, and part of the light is reflected by the second reflection portion and emitted towards the upper and lower sides of the projection screen, so that the projection light is reflected more uniformly to the front of the projection screen, and the brightness display of the projection screen is more uniform.
In addition, as shown in fig. 6 to 8, the present invention further provides a method for manufacturing a projection screen, which includes the following steps:
s1, selecting or manufacturing a die roller 50: the outer circumferential wall of the mold roller 50 is continuously provided with a reverse-grain structure 51 matched with the first lens part 111 and the second lens part 121.
S2: the die cylinder 50 is disposed in parallel with the press roller 60 at a spacing, and the die cylinder 50 can be continuously rotated. Preferably, the die roller 50 and the press roller 60 are horizontally arranged in the axial direction, and the die roller 50 and the press roller 60 are located at the same height.
S3, passing the base material film 70 between the die roller 50 and the press roller 60, and leading the base material film 70 to wind on the die roller 50 and be led out from the other side of the die roller 50; the first lens portion 111 and the second lens portion 121 are formed by transferring the reverse-grain structure 51 to the base film 70 by pressing the mold roll 50 and the press roll 60.
And S4, arranging a reflective imaging material on one side of the base material film 70 on which the first lens part 111 and the second lens part 121 are formed to form a reflective layer 13.
In the step S1, the die roller 50 has a cylindrical shape. The first lens portion 111 is matched with a first reverse-grain 511, and the second lens portion 121 is matched with a second reverse-grain 512. The first and second inverse textures 511 and 512 have the same distribution as the first and second lens portions 111 and 121. In this embodiment, the depth of the first inverse threads 511 is greater than that of the second inverse threads 512, the first inverse threads 511 are distributed at intervals in parallel, and the second inverse threads 512 are distributed between the first inverse threads 511, so that the second inverse threads 512 penetrate two adjacent first inverse threads 511. The reverse texture structure 51 is beneficial to discharging air during rolling, avoids air inclusion, and can improve the yield of products.
In step S3, when the base material film 70 passes through between the mold roller 50 and the press roller 60, the base material film 70 may be wound around the press roller 60, and then the base material film 70 passes through between the mold roller 50 and the press roller 60, so that the base material film 70 is tensioned by the press roller 60 and continuously passes through between the mold roller 50 and the press roller 60.
Further, in the step S3, the first lens portion 111 and the second lens portion 121 may be manufactured by transferring the inverse texture 51 to the base film 70 in different manners. In some embodiments, the processing may be by cold roll forming. In some embodiments, the processing may be by UV curing molding.
When the step S3 is processed by a cold rolling molding method, the step S3 specifically includes:
s311, heating the base film 70; a cooling liquid is introduced into the inside of the mold roll 50.
S312, the heated base film 70 is passed between the cooled mold roll 50 and the press roll 60, and the reverse structure 51 is transferred to the base film 70 by the pressing of the mold roll 50 and the press roll 60.
S313, the base film 70 is wound around the cooled mold roll 50, and the transferred inverse texture 51 is molded by the cooled mold roll 50, thereby forming the first lens portion 111 and the second lens portion 121.
S314, the base material film 70 is drawn out from the other side of the cooled mold roll 50, and the base material film 70 is released from the mold roll 50 by the low temperature of the mold roll 50.
In step S311, the substrate film 70 may be deformed by heating the substrate film 70, so that the reverse structure 51 may be transferred to the substrate film 70 in the subsequent step.
In step S311, the cooling zone liquid is introduced into the mold roll 50 in any manner, and is used to cool the mold roll 50 so as to facilitate cooling molding and demolding of the transferred structure. The temperature of the cold zone liquid is kept between 10 and 40 degrees. During the processing, the temperature variation of the die roller 50 is controlled to be about +/-3 degrees.
In step S312, when the heated substrate film 70 passes between the mold roll 50 and the press roll 60, the substrate film 70 is pressed and deformed by the pressure between the mold roll 50 and the press roll 60, and the reverse texture 51 is provided on the mold roll 50, so that a structure matching the reverse texture 51 can be pressed out from the substrate film 70 during the pressing process, that is, the reverse texture 51 is transferred to the substrate film 70.
In step S313, when the inverse texture 51 is transferred to the base film 70, the temperature of the base film 70 gradually decreases through the cooled mold roller 50, and when the temperature of the base film 70 is cooled to a certain temperature, the base film 70 can maintain the current shape state, so that the transferred inverse texture 51 is cooled and shaped, thereby implementing the processing of the first lens portion 111 and the second lens portion 121 on the base film 70.
The first lens portion 111 and the second lens portion 121 can be formed on the base film 70 by cold roll forming. When processed in this way, the substrate film 70 may be a transparent film, and the substrate layer 20 may be integrally formed with the first lens portion 111 and the second lens portion 121, and both sides of the projection screen may be used for projection imaging.
When the step S3 is processed by means of UV curing molding, the step S3 specifically includes:
s321, the base material film 70 passes through the space between the die roller 50 and the press roller 60, and the base material film 70 is wound on the die roller 50 and is led out from the other side of the die roller 50.
And S322, supplying liquid UV glue between the base material film 70 and the die roll 50, and enabling the liquid UV glue to enter between the reverse texture structure 51 and the base material film 70.
S323, UV irradiation is performed on the substrate film 70 wound around the mold roll 50 from the outside of the mold roll 50, and the liquid UV glue entering the embossed structure 51 and the substrate film 70 is cured and molded, so that the embossed structure 51 is transferred to the first lens portion 111 and the second lens portion 121 molded on the substrate film 70.
In step S321, the base film 70 may be passed between the die roll 50 and the press roll 60 by passing over the press roll 60, and then may be drawn out from the side of the die roll 50 by passing under the die roll 50.
In step S322, the liquid UV glue is fed between the base film 70 and the die roller 50 from above the position between the press roller 60 and the die roller 50. In order to prevent the glue from flowing out, glue blocking plates are arranged at two ends of the die roller 50 and the press roller 60, so that a containing cavity 80 capable of accumulating the liquid UV glue is formed among the glue blocking plates, the die roller 50 and the substrate film 70. When the liquid UV glue is supplied into the cavity 80, the liquid UV glue enters between the reverse structure 51 and the substrate film 70 as the mold roll 50 rotates, the substrate film 70 continuously passes through, and the mold roll 50 and the press roll 60 are pressed.
In step S323, the UV lamp 90 is disposed below the mold roller 50, and performs UV irradiation on the substrate film 70 wound around the mold roller 50, so that the liquid UV glue between the substrate film 70 and the mold roller 50 can be cured and formed. When the substrate film 70 continuously passes over the UV lamp 90 with the rotation of the mold roll 50, the liquid UV glue can be continuously cured and molded, so that the embossed structure 51 is continuously transferred onto the substrate film 70, and the first lens portions 111 and the second lens portions 121 are continuously molded on the substrate film 70.
The first lens portion 111 and the second lens portion 121 formed by UV curing molding have a composite structure with the base material layer 20. The substrate film 70 forms a substrate layer 20 of the projection screen, and may be a transparent film layer or a non-transparent film layer, which may be specifically disposed as needed. The first lens portion 111 and the second lens portion 121 are formed by curing a transparent UV paste.
In step S4, in some embodiments, the reflective layer 13 may be formed by electroplating an imaging material on the side of the base film 70 on which the first lens portions 111 and the second lens portions 121 are formed. In some embodiments, the reflective layer 13 may be formed by spraying a reflective imaging material on the side of the substrate film 70 on which the first lens portion 111 and the second lens portion 121 are formed.
In step S4, the imaging material includes, but is not limited to, metallic silver paint, pearlescent paint, etc., which should have strong reflectivity. When the metallic silver paint is selected, the granularity range of the metallic silver paint is preferably 200-2000 meshes. When the pearlescent paint is selected, the granularity range of the pearlescent paint is preferably 200-1000 meshes.
Further, in step S4, the thickness of the reflective layer 13 is less than 50 μm.
Further, the processing method can also comprise the following steps:
and S5, manufacturing a protective layer 30 on the reflecting layer 13.
While the invention has been described with reference to the above embodiments, the scope of the invention is not limited thereto, and the above components may be replaced with similar or equivalent elements known to those skilled in the art without departing from the spirit of the invention.
Claims (11)
1. A projection screen, comprising:
the optical structure functional layer (10) comprises a first optical structure (11) and a second optical structure (12), wherein the first optical structure (11) is used for reflecting the projection light along the left side and the right side of the projection screen, and the second optical structure (12) is used for reflecting the projection light along the upper side and the lower side of the projection screen.
2. The projection screen of claim 1,
the first optical structure (11) comprises a plurality of first lens parts (111) and first reflecting parts, wherein the first lens parts (111) extend from one end of a projection screen to the other end along the vertical direction, and the first reflecting parts are arranged on the first lens parts (111) and can reflect light;
the second optical structure (12) comprises a plurality of second lens parts (121) and second reflection parts, and the second reflection parts are arranged on the second lens parts (121) and can reflect light;
wherein, a plurality of second lens parts (121) are respectively arranged on the transverse direction and the vertical direction of the projection screen; the first and second reflection sections are connected to each other to form a reflection layer (13) that covers all of the first lens section (111) and the second lens section (121) on one surface.
3. The projection screen of claim 2,
the first lens parts (111) are distributed at intervals in parallel, a plurality of second lens parts (121) are arranged between every two adjacent first lens parts (111), the second lens parts (121) extend along the transverse direction, two ends of each second lens part are respectively connected with the first lens parts (111), and the distance between the second lens parts (121) positioned between every two adjacent first lens parts (111) is in a decreasing trend from bottom to top; one side surfaces of the first lens part (111) and the second lens part (121) are connected in a plane shape, and the other side surfaces are connected in a concave-convex alternating structure.
4. The projection screen of claim 2,
the top of the second lens part (121) is lower than the top of the first lens part (111).
5. The projection screen of claim 2,
the first lens part (111) is a semi-cylindrical lens, and the first reflecting part is arranged on the cylindrical surface of the semi-cylindrical lens;
the second reflection part is provided on the surface of the second lens part (121) on the same side as the cylindrical surface.
6. A projection screen according to claim 2 wherein a substrate layer (20) is provided on the surface of the optically structured functional layer (10) opposite the reflective layer (13).
7. A projection screen according to claim 2, wherein a transparent protective layer (30) is provided on the surface of the reflective layer (13) on the side opposite to the first lens portion (111).
8. A method of manufacturing a projection screen according to any one of claims 2 to 7, comprising the steps of:
s1, selecting or manufacturing a die roller (50): the outer circumferential wall of the die roller (50) is continuously provided with a reverse texture structure (51) matched with the first lens part (111) and the second lens part (121);
s2: arranging the die roller (50) and the press roller (60) in parallel at intervals, wherein the die roller (50) can continuously rotate;
s3, passing the base material film (70) between the die roller (50) and the press roller (60), and leading the base material film (70) to wind on the die roller (50) and be led out from the other side of the die roller (50); transferring the reverse texture (51) to the base film (70) by pressing with a die roller (50) and a press roller (60) to form the first lens part (111) and the second lens part (121); and S4, spraying a reflective imaging material on one side of the base material film (70) on which the first lens part (111) and the second lens part (121) are formed to form a reflective layer (13).
9. The method for manufacturing a projection screen according to claim 8, wherein the step S3 specifically comprises:
s311, heating the base material film (70); introducing cooling liquid into the die roller (50);
s312, passing the heated base material film (70) between a cooled die roller (50) and a pressure roller (60), and transferring the reverse texture structure (51) to the base material film (70) through the extrusion of the die roller (50) and the pressure roller (60);
s313, winding the base material film (70) on a cooled mold roller (50), and forming the transferred inverse texture structure (51) through the cooled mold roller (50) to process the first lens part (111) and the second lens part (121);
s314, the base material film (70) is led out from the other side of the cooled die roller (50), and the base material film (70) and the die roller (50) are released through the low temperature of the die roller (50).
10. The method for manufacturing a projection screen according to claim 8, wherein the step S3 specifically comprises:
s321, enabling the base material film (70) to pass through the space between the die roller (50) and the press roller (60), and enabling the base material film (70) to wind on the die roller (50) and be led out from the other side of the die roller (50);
s322, supplying liquid UV glue between the base material film (70) and the die roll (50), and enabling the liquid UV glue to enter between the reverse texture structure (51) and the base material film (70) through extrusion of the press roll (60) and the die roll (50);
s323, UV irradiation is carried out on the base material film (70) wound on the die roller (50) from the outer side of the die roller (50), the liquid UV glue entering the reverse texture structure (51) and the base material film (70) is solidified and molded, and the reverse texture structure (51) is transferred to the first lens part (111) and the second lens part (121) molded on the base material film (70).
11. The method of claim 10, wherein the step of forming the projection screen includes the steps of,
the base material film (70) passes between the die roller (50) and the press roller (60) by passing over the press roller (60);
the liquid UV glue is fed between the base film (70) and the die roll (50) from above a position between the press roll (60) and the die roll (50);
and glue blocking plates for preventing the liquid UV glue from flowing outwards are arranged at two ends of the die roller (50) and the press roller (60).
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| CN115202144B (en) | 2022-12-13 |
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