EP1500266A2

EP1500266A2 - Method and apparatus for a light weight enclosure for projection televisions

Info

Publication number: EP1500266A2
Application number: EP03731040A
Authority: EP
Inventors: Darin Bradley Ritter; Steve Lewis Cunningham; Neal Kenneth Jacobs
Original assignee: Thomson Licensing SAS
Current assignee: Thomson Licensing SAS
Priority date: 2002-04-26
Filing date: 2003-04-22
Publication date: 2005-01-26
Also published as: WO2003090511A2; AU2003241309A1; CN1647515A; KR20040104623A; KR100978163B1; MXPA04010510A; WO2003090511A3; JP2005524257A; JP4583031B2; CN100576895C; AU2003241309A8

Abstract

A projection display apparatus includes a plastic upper cabinet (300) including a display device in optical cooperation with a reflection means, the plastic upper cabinet (300) having a bottom perimeter substantially conforming to a top perimeter of a plastic lower cabinet (400), and the plastic lower cabinet (400) including an optics frame (500) for supporting optical components, the second cabinet (400) comprising an enclosure (403) for inserting the optics frame (500) such that the optics frame (500) fits snugly into the enclosure (403) increasing the rigidity of the second cabinet (400), the plastic lower cabinet (400) having a bottom perimeter substantially conforming to a top perimeter of a plastic floor interface (600), the plastic upper cabinet (300) and the plastic lower cabinet (400) being separately formed and detachably attached.

Description

METHOD AND APPARATUS FOR A LIGHT WEIGHT ENCLOSURE FOR PROJECTION TELEVISIONS

This application claims priority to U.S. Provisional Application No. 60/376,098 filed in the U.S. on April 26, 2002.

FIELD OF THE INVENTION

This invention relates to the field of television enclosures and, more specifically, to projection television cabinets.

BACKGROUND OF THE INVENTION Projection televisions comprise a cabinet containing a video projector and a video screen optically aligned by one or more mirrors. Such cabinets are typically very big and very heavy, and the various optical elements enclosed therein must be carefully aligned. If the video projector elements and mirrors inside the cabinet are moved in relation to the screen, the image will be poor because proper convergence will be destroyed resulting in color fringing. Typically, projection television cabinets are comprised of a combination of wood, metal, and plastic having a large mass that inherently resists misaligning forces. The metal is generally of high bending strength resistant to distortion.

For example, a projection television 100 shown in FIG. 1 has a configuration wherein wood plate materials are used. The plate materials are formed into a box, which comprises a main body portion 120 and a bottom cabinet 170. A screen mounting frame 140 is mounted onto the front of the main body portion 120 for installing a screen 130. A mirror mounting enclosure 160 is mounted to the rear of the main body portion 120 for installing a mirror 150. The bottom cabinet 170 is adapted for containing the video devices and electronic components.

The size of the main body portion 120 and the overall size of the television, including the mirror mounting portion 160, are determined by the size of a projection screen to be used. Each part of the housing is formed with a size and dimensional accuracy originally designed to provide a single housing that depends on the size of the projection screen. As a result, such parts are not compatible with other size projection screens. A projection television 200 shown in FIG. 2 has a configuration wherein a metal frame 280 in a predetermined shape is placed on a bottom cabinet 270. A screen mounting frame 240 including a screen 230, and a mirror mounting enclosure 260 including a mirror 250, are integrally mounted to envelope the frame 280. In the projection television 200 of FIG. 2, the metal frame 280 used is designed as a housing of one size in accordance with the size of a projection screen. As a result, there is no compatibility with other projection screen sizes.

The use of wood and high bending strength metal to form cabinets for projection televisions is considered necessary to achieve a level of rigidity that enables projection televisions to be delivered to a customer without degradation in the image quality due to shipping and handling. Unfortunately, the use of wood and metal results in cabinets that are heavy, costly, and that lack compatibility with varied projection screen sizes.

SUMMARY OF THE INVENTION

The invention comprises a method and apparatus for an interchangeable, light weight enclosure for display devices such as projection televisions. The enclosure according to the principles of the invention includes upper and lower cabinets, which are detachably attached. The lower cabinet, which is supported by a floor interface, supports the upper cabinet and includes an enclosure for inserting an optics frame. The optics frame supports optical components for presenting images or video signals. To make the enclosure light, the lower cabinet can be made of low bending strength material that normally is light in weight. However, the optics frame is made of higher bending strength material (such as steel) and the enclosure is designed such that when the optics frame is inserted, the optics frame prevents side walls of the lower cabinet from moving toward each other, thereby stiffens the lower cabinet.

In one embodiment, the upper and lower cabinets, and the floor interface are made of plastic. The upper cabinet has a locator that mates with a locator in the lower cabinet, such that the lower cabinet restricts lateral movements of the upper cabinet.

In another embodiment, a projection display apparatus includes a plastic upper cabinet including a display device in optical cooperation with a reflection means, the plastic upper cabinet having a bottom perimeter substantially conforming to a top perimeter of a plastic lower cabinet, and the plastic lower cabinet including an optics frame for supporting optical components, the plastic lower cabinet comprising an enclosure for inserting the optics frame such that the optics frame fits snugly into the enclosure increasing the rigidity of the plastic lower cabinet, the plastic lower cabinet having a bottom perimeter substantially conforming to a top perimeter of a plastic floor interface, the plastic upper cabinet and the plastic lower cabinet being separately formed and detachably attached.

BRIEF DESCRIPTION OF THE DRAWINGS

The teachings of the present invention can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which:

FIG. 1 depicts an exploded perspective view of a typical wood frame cabinet for a projection television;

FIG. 2 depicts an exploded perspective view of a typical metal frame cabinet for a projection television;

FIG. 3 depicts an exploded isometric view of an embodiment of a projection television enclosure in accordance with the present invention; FIG. 4 depicts an exploded front view of the projection television enclosure of

FIG. 3;

FIG. 5 depicts an exploded side view of the projection television enclosure of FIG. 3;

FIG. 6 depicts an exploded top view of the projection television enclosure of FIG. 3;

FIG. 7 depicts a top view and a bottom view of a lower cabinet of the projection television enclosure of FIG. 3; and

FIG. 8 depicts an exploded view of a joint between a circular pocket of an upper cabinet and a circular pocket of a lower cabinet of the projection television enclosure of FIG. 3.

To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. DETAILED DESCRIPTION OF THE INVENTION The subject invention will be described within the context of a rear projection television and associated devices. However, it will be appreciated by those skilled in the art that the subject invention may be advantageously applied for any projection television or, generically, display device using projection techniques. Thus, it is contemplated by the inventors that the subject invention has broad applicability beyond the rear projection television system described herein. The invention may be used to provide a light weight, stable, interchangeable enclosure for front or rear projection televisions or display devices of varied screen sizes.

The projection television enclosure of the present invention will be described with reference to FIGs. 3 through 8, which include commonly designated elements. The projection television enclosure includes an upper cabinet 300, a lower cabinet 400, and a floor interface 600. Additionally, an optics frame 500 is illustrated in the projection television enclosure of the present invention, for supporting all of the optics required for a rear projection television, excluding a screen and a mirror, which are provided in the upper cabinet 300. The optics frame 500 is configured in the form of a cartridge as a whole and is inserted into the lower frame 400 for providing rigidity to the lower frame 400. The upper cabinet 300, the lower cabinet 400 and the floor interface 600 are formed independently of each other. Although the floor interface 600 of the projection television enclosure depicted in figures 1-8 is shown as a separate component, the floor interface 600 can be advantageously implemented as being substantially integrated into the lower cabinet 400.

The components of the projection television enclosure of figures 1-8 are formed such that the lower cabinet 400 is assembled onto the floor interface 600, and in turn, the upper cabinet 300 is mounted on the assembly of the lower cabinet 400 and the floor interface 600. This advantageously allows for a screen size of the upper cabinet 300 to be arbitrarily selected with respect to the lower cabinet 400. That is, an upper cabinet 300 of any screen size, e.g., 37 inches, 50 inches or more, can be used with a common lower cabinet 400. This is accomplished by forming a bottom wall of the upper cabinet 300 in a substantially similar geometric design, with respect to the coupling and mounting components, for all of the upper cabinets of different screen sizes. As such, the length of the lower cabinet 400 at the screen side may be different from that of the upper cabinet 300. Preferably, the lower cabinet 400 is first made for the smallest screen size, such as 37 inches, so that the lower cabinet 400 has a length of about the smallest screen size on the screen side, i.e., about the same length of the upper cabinet 300 made for the smallest screen size. For other screen sizes, therefore, the length of the upper cabinet 300 on the screen side is longer than that of the lower cabinet 400. Of course, depending on the range of the screen sizes to be supported, one may select a size of the lower cabinet that is larger than necessary for the smallest screen size, so that the same lower cabinet 400 can be used for the largest screen size. In this case, the length of the upper cabinet 300 on the screen side may be smaller than the lower cabinet 400. This makes it possible to manufacture projection televisions having different sizes easily by simply changing the upper cabinet 300. Additionally, the upper cabinet 300, lower cabinet 400, and floor interface 600 are advantageously manufactured of a light weight material capable of being mass produced. The light weight material reduces the weight of the projection television enclosure and the simplicity of manufacture decreases the time and costs associated with the projection television enclosure. In the figures presented herein, the light weight material is plastic and the manufacturing process is injection molding. Various plastics are known to those skilled in the art. However, the light weight material is not limited to plastics, other materials such as aluminum can be used as well.

The upper cabinet 300 provides an enclosure for a display device in optical cooperation with a reflection means to locate an image from the image forming optics of the projection television. In one embodiment of the invention the display device is a screen and the reflection means is a mirror working in cooperation to locate the image of a picture onto the screen. The upper cabinet 300 is formed with a rectangular frame portion 302 on a front side thereof. The upper cabinet 300 is formed by a top wall 304, two side walls 306ι, 306₂, (collectively side walls 306), a rear wall 308, and a bottom wall 310 in the form of a box as a whole, with an open front face. The bottom wall 310 is formed with an opening to which faces the projection lens, when it is assembled with the lower cabinet 400. The top wall 304, two side walls 306, and bottom wall 310 flare out toward the front side as a whole, to accommodate screens and mirrors of larger sizes.

The bottom wall 310 is formed with two flanges (overlapping walls) 312ι and 312₂ (collectively flanges 312) that run along the length of the two side walls 306 on the inside of the upper cabinet 300. The flanges 312 are used for coupling the upper cabinet 300 with the lower cabinet 400. Specifically, the flanges 312 of the upper cabinet 300 mate with ledges 412, described below, on the lower cabinet 400. The flanges 312 are each formed with a front face 313ι and 313₂ (collectively front faces 313) each containing a circular pocket 314ι and 314₂ (collectively circular pockets 314) disposed thereon. The circular pockets 314 mate with two circular pockets 422, described below, on the lower cabinet 400.

The upper cabinet 300 also includes a central "hump" 320. The central hump 320 is formed as a part of the bottom wall 310. The central hump 320 aids in the mechanical coupling between the upper cabinet 300 and the lower cabinet 400 to provide greater strength and stability for the enclosure. The central hump 320 also improves the strength and stability of the enclosure by transferring the load from the top of the upper cabinet 300, to the more stable base of the upper cabinet 300. The central hump 320 is formed with a forward flange 321 , two screw holes 322i and 322₂ (collectively screw holes 322), and two screw mounting tabs 323ι and 323₂ (collectively screw mounting tabs 323) along the front face of the central hump 320. The forward flange 321 on the central hump 320 mates with a ledge 410, described below, on the lower cabinet 400. The two screw holes 322 mate with screw holes 414 on a rear wall 416, described below, of the lower cabinet 400. The two screw mounting tabs 323 mate with holes 418 on the rear wall 416, described below, of the lower cabinet 400. It will be appreciated by those skilled in the art that various combinations of ledges, flanges, screw mounting tabs, and screw holes can be formed in the upper cabinet 300 for mounting the upper cabinet 300 to the lower cabinet 400. An important aspect is that a substantial portion of the bottom perimeter of the upper cabinet 300 be supported by the lower cabinet 400 such that the load of the upper cabinet 300 is supported in a stable manner by the lower cabinet 400. In this manner, fastening hardware (e.g., screws, bolts, set screws, etc.) used to fasten the upper cabinet 300 to the lower cabinet 400 do not experience excessive load or stress.

All of the optics required for a rear projection television are provided in an optics frame 500 in the lower cabinet 400, excluding a screen and a mirror that are provided in the upper cabinet 300 as described above. The optics frame 500 is configured in the form of a cartridge as a whole so that it can be easily replaced from the front side. The optics frame 500 is formed with two sheet metal endplates 502ι and 502₂ (collectively endplates 502) and two sheet metal rails 510ι and 510₂ (collectively rails 510). Thus, in this embodiment, the optics frame 500 is stronger and more rigid than the lower cabinet 400, which is made of plastic. The endplates 502 and the rails 510 support Optronics, which produce the picture. Each endplate 502 is formed with a top edge, collectively 506, and a bottom fold, collectively 520. The two top edges 506 mate with two ledges 424 of protruding blocks 431 , described below, on the lower cabinet 400. This mate enables the optics frame 500 to prevent the upper portion of the side walls 404 of the lower cabinet 400 from moving toward each other. The two bottom folds 520 mate with two ledges 426, described below, on the lower cabinet 400. A front edge 503 of each endplate 502 mates with two side faces 428 of jutting blocks 438, described below, to center the optics frame 500 in the lower cabinet 400 for installation. The mate of the jutting blocks 438 and the endplates enables the optics frame 500 to prevent the lower portion of the side walls 404 of the lower cabinet 400 from moving toward each other. The top of the back edge of each endplate 502 is formed with a screw mounting tab, collectively 504. The two screw mounting tabs 504 mate with two screw holes 430 on protruding blocks 431 , described below, on the lower cabinet 400. The back edge of each bottom fold 520 is also formed with a screw mounting tab, collectively screw mounting tabs 521. The two screw mounting tabs 521 mate with two screw holes 432, described below, on the lower cabinet 400.

When the optics frame 500 is mounted onto the lower cabinet 400, the optics frame 500 fits tightly into the lower cabinet 400, such that the sheet metal endplates 502 of the optics frame 500 stiffen the structure of the lower cabinet 400. The inventors have determined that stiffening the lower cabinet 400 with the optics frame 500 is important for providing the necessary rigidity for the projection television enclosure of the present invention. Once again, it will be appreciated by those skilled in the art that various combinations of ledges, flanges, screw mounting tabs, and screw holes can be formed in the optics frame 500 for mounting the optics frame 500 to the lower cabinet 400. An important aspect is that a substantial portion of the perimeter of the optics frame 500, except for the front face, be supported by the lower cabinet 400 such that the load of the optics frame 500 is supported in a stable manner by the lower cabinet 400.

The lower cabinet 400 is a convoluted thin walled structure. The lower cabinet 400 is designed to support the upper cabinet 300 and encompass and support the optics frame 500, such that the load of the upper cabinet 300 and the optics frame 500 are transferred to the lower cabinet 400 in a manner limiting the stress on any fastening hardware. Additionally, the lower cabinet 400 can also be formed to contain speakers for the projection television. The lower cabinet 400 is formed with a generally rectangular shape. If speakers are to be contained in the lower cabinet 400, two additional rectangular rear cabinets are provided substantially integrated as a part of a rear wall of the lower cabinet 400.

The lower cabinet 400 is formed by a top wall 402, two side walls 404-_I, 404₂, (collectively side walls 404), a rear wall 416, and a bottom wall 408 in the form of a box as a whole with a partially open front face. The embodiment depicted in the FIGs herein, also depict two additional rectangular rear cabinets 415-i and 415₂ (collectively rear cabinets 415) for housing speakers.

The front face of the lower cabinet 400 is formed with two circular pockets 422ι and 422₂ (collectively circular pockets 422) in the upper two corners of the front face of the lower cabinet 400. As described above, the circular pockets 422 of the lower cabinet 400 mate with the circular pockets 314 of the upper cabinet 300 to locate the upper cabinet 300 on the lower cabinet 400. These pocket pairs together enable the lower cabinet 400 to restrict lateral movements of the upper cabinet 300. Lateral movements as used herein are defined as movements in the direction pointing from one of the two side walls 306 to the other side wall. An exploded view of this joint is depicted more clearly in FIG. 8.

The junctions between the top wall 402 and the side walls 404 of the lower cabinet 400, form ledges 412i and 412₂ (collectively ledges 412), substantially coextensive with the width of the lower cabinet 400. As described above, the ledges 412 of the lower cabinet 400 mate with the flanges 312 of the upper cabinet 300. The center of the top wall 402 is formed with a raised, partial cut-out 406, formed for adaptation as an optics locator for locating the optics (i.e., the cathode ray tubes) of the optics frame 500. See FIG. 5 for details. The back edge of the raised partial cutout forms a ledge 410. As described above, the ledge 410 of the lower cabinet 400 mates with the forward flange 321 on the central hump 320 of the upper cabinet 300. The rear wall 416 of the lower cabinet 400 is formed with two screw holes 414ι and 414₂ (collectively screw holes 414) located on the rear wall 416 on both ends of the raised optics locator 406. As described above, the two screw holes 414 on the rear wall 416 mate with the two screw holes 322 on the central hump 320 of the upper cabinet 300. The rear wall 416 is formed to also include two other screw holes 418₁ and 418₂ (collectively screw holes 418). The two screw holes 418 are located on the back wall 416 such that the screw holes 418 mate with the two screw mounting tabs 323 on the central hump 320 of the upper cabinet 300. Additionally, the rear wall 416 is formed with a plurality of screw holes 420 (illustratively 4 screw holes 420) to mate with screw mounting tabs 620, described below, on the floor interface 600. See FIG. 4. The rear cabinets 415 on the rear wall 416 are each formed with a screw hole 417ι and 417₂ (collectively screw holes 417) near the bottom of each of the rear cabinets 415. The two screw holes 417 mate with screw mounting tabs 617, described below, on the floor interface 600. Additionally, each rear cabinet 415 is formed with a protruding ledge 446ι and 446₂ (collectively ledges 446) on the base of the cabinet. The protruding ledges 446 mate with edges 618, described below, of the floor interface 600. The bottom wall 408 of the lower cabinet 400 is designed to mate with the floor interface 600. The two ends of the bottom wall 408 are slightly raised and extend toward the side walls 404, connecting with the side walls 440 of the front face of the cavity 403 and forming two ledges 434ι and 434₂ (collectively ledges 434). Similarly, the two ends of the side walls 404 are slightly raised and extend toward the center of the bottom wall 408, forming two ledges 436ι and 436₂ (collectively ledges 436). The ledges 434 and 436 form channels that mate with two protruding arms 611 , described below, on the floor interface 600. The channel-protruding arm pairs enable the floor interface 600 to restrict lateral movement of the lower cabinet 400.

The lower cabinet 400 is also formed with an internal cavity 403 for providing clearance for the optics (i.e., the cathode ray tube parts) of the optics frame 500 and the optics frame 500, itself. The cavity 403 is open toward the front face of the lower cabinet 400 for inserting the optics frame 500 into the lower cabinet 400.

The front face of the cavity 403 of the lower cabinet 400 is defined by two protruding blocks 431₁ and 431₂ (collectively protruding blocks 431) located at the top of the front face of the cavity 403, two jutting blocks 438ι and 438₂ (collectively jutting blocks 438) located near the top of the front face of the cavity 403, two side walls 440ι and 440₂ (collectively side walls 440) of the front face of the cavity 403, and a bottom wall 408 of the front face of the cavity 403.

A front face of each of the protruding blocks 431 of the cavity 403 is formed with a screw hole 430ι and 430₂ (collectively screw holes 430). As described above, the two screw holes 430 mate with the two screw mounting tabs 504 of the optics frame 500. A side face of each of the protruding blocks 431 of the cavity 403 forms two ledges 424ι and 424₂ (collectively ledges 424). As described above, the two ledges 424 mate with the two top edges 506 of the endplates 502 of the optics frame 500. The jutting blocks 438 on the front face of the cavity 403 are each formed with a side face 428ι and 428₂ (collectively side faces 428). As described above, the two side faces 428 of the jutting blocks 438 mate with the front edges 503 of each endplate 502 of the optics frame 500.

The two side walls 440 defining the cavity 403 form two ledges 426ι and 426₂ (collectively ledges 426). As described above, the two ledges 426 of the side walls 440 mate with the two bottom folds 520 of the optics frame 500. The side walls 440 are formed with two screw holes 432ι and 432₂ (collectively screw holes 432) located near the top of the front face of the side walls 440. As described above, the two screw holes 432 mate with the two screw mounting tabs 521 of the optics frame 500. Additionally, the side walls are also formed with two screw holes 444ι and 444₂ (collectively screw holes 444) located near the bottom of the front face of the side walls 440. The two screw holes 444 mate with two screw mounting tabs 644, described below, on the floor interface 600.

It will be appreciated by those skilled in the art that various combinations of ledges, flanges, screw mounting tabs, and screw holes can be formed in the lower cabinet 400 for mounting the lower cabinet 400 to the floor interface 600. An important aspect is that a substantial portion of the bottom perimeter of the lower cabinet 400 be supported by the floor interface 600 such that the load of the lower cabinet 400 is supported in a stable manner by the floor interface 600. In this manner, fastening hardware (e.g., screws, bolts, set screws, etc.) used to fasten the lower cabinet 400 to the floor interface 600 does not experience excessive load or stress.

The floor interface 600 is a relatively thin walled structure that can optionally be formed with a plurality of ribs added for stiffening. The floor interface 600 can also optionally include casters 630 on the bottom to provide mobility. The floor interface 600 is designed to receive and support the lower cabinet 400, such that the load of the lower cabinet 300 is transferred to the floor interface 600 in a manner limiting the stress on any fastening hardware. The floor interface 600 is formed with a generally rectangular shape with the addition of two protruding arms extending from the front ends of a rectangular body. A rectangular body 610 of the floor interface 600 is formed by a top wall 601 , two side walls 602ι, 602₂, (collectively side walls 602), a rear wall 603, a bottom wall 604, and a front wall 605, in the form of a box as a whole with a partially open front face. The two protruding arms 6111, 611₂, (collectively protruding arms 611 ) of the floor interface 600 are formed by top wall 612, two outside walls 613-i, 613₂, (collectively outside walls 613), two inside walls 614ι, 614₂, (collectively inside walls 614), a bottom wall 615, and a front wall 616. The outside walls 613 of the protruding arms 611 extend laterally beyond the side walls of the rectangular body 610 to form two edges 618ι, 618₂, (collectively edges 618). As described above, the two edges 618 mate with the protruding ledges 446 on the base of the rear cabinets 415 of the lower cabinet 400. As described above, the two protruding arms 611 , themselves, mate with channels 435 of the lower cabinet 400. The front wall 605 of the rectangular body 610 of the floor interface 600 is formed with a plurality of screw mounting tabs 620 (illustratively 4 screw mounting tabs 620), located along the top edge of the front wall 605. As described above, the plurality of screw mounting tabs 620 mate with the plurality of screw holes 420 on the rear wall 416 of the lower cabinet 400.

The front wall 616 of each of the protruding arms 611 of the floor interface 600 is formed with a screw mounting tab 644ι and 644₂ (collectively screw mounting tabs 644), located along the top edge of each of the front walls 616. As described above, the screw mounting tabs 644 mate with the two screw holes 444 located near the bottom of the front face of the side walls 440 of the lower cabinet 400.

The top wall 612 of the rectangular body 610 of the floor interface 600 is formed with two screw mounting tabs 617ι and 617₂ (collectively screw mounting tabs 617), located on the top wall 612 along the top edge of the side walls 602 at a distance from the front wall 605 enough to mate with the two screw holes 417 near the bottom of each of the rear cabinets 415 on the lower cabinet 400.

It will be appreciated by those skilled in the art that various combinations of ledges, flanges, screw mounting tabs, and screw holes can be formed in the floor interface 600 for mounting the lower cabinet 400 to the floor interface 600. An important aspect is that a substantial portion of the bottom perimeter of the lower cabinet 400 be supported by the floor interface 600 such that the load of the lower cabinet 400 is supported in a stable manner by the floor interface 600. In this manner, fastening hardware (e.g., screws, bolts, set screws, etc.) used to fasten the lower cabinet 400 to the floor interface 600 does not experience excessive load or stress. When assembled together, the upper cabinet 300, the lower cabinet 400 including the optics frame 500, and the floor interface 600, provide a projection television enclosure that is substantially rigid enough to prevent the degradation in an image of the projection television due to moving components in a material that is light weight and advantageously allows for mass production. Although in the embodiment depicted above, various holes and tabs were depicted and described as "screw" holes and "screw" mounting tabs, it will be appreciated by those skilled in the art, that various other forms of fasteners (i.e., bolts, set screws, and the like, as well as glue and the like) can also be advantageously implemented to fasten the various components. In addition, it will also be appreciated by those skilled in the art that, although specific numbers of the holes and the tabs were illustrated in the embodiment of the present invention depicted in the various figures herein, other numbers of holes and tabs can be advantageously implemented in alternate embodiments of the present invention. The number of holes and tabs ultimately implemented to fasten the enclosure of a projection television, in accordance with the present invention, depends on the fastening necessary or desired in a projection television and the number of components utilized. An important aspect is that the various components of the present invention interlock in a manner to supply the rigidity necessary for a projection television to prevent the degradation in an image of the projection television due to moving components. In addition, the inventors provide this important aspect in a material that is light weight and in a method that advantageously allows for mass production of the proposed projection television enclosure.

While the forgoing is directed to some embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. As such, the appropriate scope of the invention is to be determined according to the claims, which follow.

Claims

1. A display device enclosure, comprising: a first cabinet (300) disposed on top of a second cabinet (400); and said second cabinet (400) comprising an enclosure (403) for inserting an optics frame (500) for supporting optical components, said second cabinet (400) disposed on top of a floor interface (600), wherein said first and second cabinets are detachably attached, said optics frame (500) and the second cabinet (400) are made of first and second materials, respectively, said first material has higher bending strength than the second material such that when said optics frame (500) is inserted into said enclosure (403), said optics frame (500) prevents side walls (404) of said second cabinet (400) from moving toward each other.

2. The display device enclosure of claim 1 , wherein said first cabinet (300) and second cabinet (400) and said floor interface (600) are made of plastic, said first cabinet (300) having a first locator (314) mating with a second locator (422) such that said second cabinet (400) restricts lateral movement of said first cabinet (300).

3. The display device enclosure of claim 2, wherein said second cabinet (400) has a channel (435) mates with a protruding arm (611 ) of said floor interface (600) such that said floor interface (600) restricts lateral deformation of said bottom wall (408) of said lower cabinet (400).

4. The display device enclosure of claim 2, wherein said second material is metal.

5. The display device enclosure of claim 2, wherein said second cabinet (400) includes two bottom ledges (426) extending from a bottom face (408) and two top ledges (424) extending from a top face (402) of said second cabinet (400), the top ledges (426) mate with two bottom folds (520) of said optics frame (500), and the bottom ledges (424) mate with two top edges (506) of said optics frame 500.

6. The display device enclosure of claim 2, wherein said second cabinet (400) is adapted to cooperate with a plurality of first cabinets, and wherein each of said plurality of first cabinets is adapted to receive a respectively sized display device.

7. The display device enclosure of claim 6, wherein said display devices are screens.

8. The display device enclosure of claim 2, wherein said optics frame (500) is disposed within the enclosure (403) of said second cabinet 400 to increase the rigidity of said second cabinet (400).

9. The display device enclosure of claim 2, wherein said first cabinet (300), said second cabinet (400), and said floor interface (600) are formed by injection molding.

10. The display device enclosure of claim 2, wherein said floor interface (600) is substantially integrated as a part of said second cabinet (400).

11. A projection display apparatus comprising: a first cabinet (300) including a display device in optical cooperation with a reflection means, said first cabinet (300) disposed on top of a second cabinet (400) and having a bottom perimeter substantially conforming to a top perimeter of said second cabinet (400); and said second cabinet (400) including an optics frame (500) for supporting optical components, said second cabinet (400) comprising an enclosure (403) for inserting said optics frame (500) such that said optics frame (500) fits snugly into said enclosure (403) increasing the rigidity of said second cabinet (400), said second cabinet (400) disposed on top of a floor interface (600) and having a bottom perimeter substantially conforming to a top perimeter of said floor interface (600), said first cabinet (300) and said second cabinet (400) being made of plastic and being separately formed and detachably attached.

12. The projection display apparatus of claim 11 , wherein said display device is a screen.

13. The projection display apparatus of claim 11 , wherein said first cabinet (300), said second cabinet (400), and said floor interface (600) are formed by injection molding.

14. The projection display apparatus of claim 11 , wherein said floor interface (600) comprises stiffening ribs.

15. The projection display apparatus of claim 11 , wherein said floor interface (600) further comprises casters (630).

16. A method for providing a display device enclosure, comprising: forming a first cabinet (300) from plastic, said first cabinet (300) disposed on top of a second cabinet (400) and having a bottom perimeter substantially conforming to a top perimeter of said second cabinet (400), wherein a substantial portion of the bottom perimeter of said first cabinet (300) is supported by said second cabinet (400) such that a load transferred from said first cabinet (300) to said second cabinet (400), when coupled together, is supported by said second cabinet (400); forming said second cabinet (400) from plastic, said second cabinet (400) comprising an enclosure (403) for inserting an optics frame (500) such that said optics frame (500) when inserted fits snugly into said enclosure (403) increasing the rigidity of said second cabinet (400), said second cabinet (400) disposed on top of a floor interface (600) and having a bottom perimeter substantially conforming to a top perimeter of said floor interface (600); and forming said floor interface (600) from plastic, said floor interface (600) being formed to couple with said second cabinet (400).

17. The method of claim 16, wherein said second cabinet (400) is formed to adapt to cooperate with a plurality of first cabinets, wherein each of said plurality of first cabinets comprises a bottom perimeter substantially conforming with said top perimeter of said second cabinet (400), and wherein each of said plurality of upper cabinets is adapted to receive a respectively sized display device.

18. The method of claim 17, wherein said display devices are screens.

19. The method of claim 16, wherein said floor interface (600) comprises stiffening ribs.

20. The method of claim 16, wherein said floor interface (600) is substantially integrated as a part of said second cabinet (400).