KR0156205B1 - Method & apparatus for manufacturing projection screen - Google Patents

Abstract

The present invention relates to a transmissive projection screen and an apparatus for manufacturing the same, and when the structure of the front screen part is changed and used, the resolution is increased as the light passing through the Fresnel lens and the external light obliquely incident to the rear screen part are blocked. In addition to providing a transmissive projection screen, a transmissive projection screen enables mass production of a transmissive projection screen to block the incident light and external light incident to the rear screen portion so as to increase the resolution and at a low manufacturing cost. It is intended to provide.

To this end, the present invention provides a plurality of front microlenses protruding blocks while forming a checkerboard shape on the front screen portion of the screen body, a plurality of rear microlenses protruding convexly while forming a checkerboard shape on the rear screen portion of the screen body, and the respective angles. Providing a transmissive projection screen composed of a projection piece formed on the boundary surface of the front microlens and a black film formed on the end of the projection piece; Continuously discharging the molten acrylic resin into a plate-like acrylic sheet, and forming a plurality of rear microlenses to form a checkerboard on one surface of the plate-shaped acrylic sheet discharged by the process, and protruding to the boundary surface of each front microlens Forming a piece, cooling the screen body on which the rear microlens, the front microlens and the protruding piece are formed by the step, and applying a black film to the end of the protruding piece of the screen body cooled by the step. It provides a method of manufacturing a transmissive projection screen made sequentially; A plurality of checkerboard-type rear microlenses are formed on one surface of the hopper which discharges the acrylic resin melted by the high temperature to the plate-shaped acrylic sheet and rotatably installed at the rear of the hopper and discharged from the hopper to the plate. A plurality of front microlenses having a checkerboard shape are formed on the other surface of the lower roll mold and the other side of the sheet which is rotatably installed at the rear of the hopper and discharged into the plate form from the hopper to form a projection piece at the boundary of each front microlens with zoom The upper roll mold and the upper and lower roll molds are installed at the rear, and the lower roll mold is provided with a plurality of front microlenses on the sheet, and the lower roll mold is formed with a plurality of rear microlenses and protrusions on the sheet. Cooler for cooling the body, rotatably installed at the rear of the cooler to cool by the cooler It provides a device for manufacturing a transmissive projection screen consisting of a plurality of guide rollers for guiding the transfer of the screen body, and a printing roller rotatably installed to the rear of the cooler to apply a black film to the end of the protruding piece formed on the screen body. do.

Description

Method and apparatus for manufacturing a transmission projection screen

1 is a perspective view showing a conventional transmissive projection screen.

2 is a side view for explaining the state of use of the conventional transmissive projection screen.

3 is a schematic view showing a device for manufacturing a conventional transmissive projection screen.

4 is a plan view showing a transmissive projection screen of the present invention.

5 is a cross-sectional view taken along the line A-A of FIG.

6 is a side view for explaining a state of use of the transmissive projection screen of the present invention.

7 is a flowchart for explaining a process of manufacturing a transmissive projection screen of the present invention.

8 is a front view schematically showing a device for manufacturing the transmissive projection screen of the present invention.

* Explanation of symbols for main parts of the drawings

1: screen body 2: front microlens

3: rear microlens 4: protrusion

5: black film 21: hopper

22: lower roll mold 22a: lower roll indentation groove

23: upper roll mold 23a: first upper roll insertion groove

23b: second upper roll indentation groove 24: cooler

25: guide roller 26: printing roller

27: checker

The present invention relates to a transmissive projection screen and a method and apparatus for manufacturing the transmissive projection screen used in LCD projectors and the like to form an image, and more particularly, to block the incident light inclined when using the external In order to provide a transmissive projection screen to block the light to increase the resolution, and to provide a method and apparatus for manufacturing a transmissive projection screen to enable mass production of the above-mentioned transmissive projection screen with a small manufacturing cost.

In the conventional transmission projection screen, as shown in FIG. 1 of the accompanying drawings, the front screen of the screen body 1 has a plurality of front microlenses 2 protruding from the block while forming a checker board shape, and the screen body 1 The rear screen portion of the) is a structure in which a plurality of rear microlenses 3 protrudingly convex while forming a checkerboard shape are formed.

When the apparatus is operated while the transmissive projection screen is used as described above, the light projected by the enlarged projection lens (not shown) passes through the Fresnel lens and is incident on the transmissive screen to form an image.

That is, when light passing through the Fresnel lens is incident on the plurality of rear microlenses 3 formed on the rear surface of the screen body 1, the incident light is provided on the front surface of the screen body 1. As one point of (2) is collected and then enlarged and spread, an image is formed on the front microlens. At this time, the light passes through the Fresnel lens and enters into the rear microlens 3 of the screen body 1 in parallel (rear smile). The light that is not incident and is inclined by a predetermined angle θ is not incident and forms an image on the front microlens right next to the front microlens 2 formed by the parallel incident light. The resulting images overlap, resulting in a drop in resolution.

In addition, if the user operates the device while the fluorescent light or other light source is turned on in the room, the external light is reflected by the front microlens 2 of the screen body 1, and thus worsens the contrast of the image formed on the screen. It was another cause to drop.

Meanwhile, the longitudinal cooling projection screen is manufactured by a device as shown in FIG. 3, which will be described in detail below.

A lower plate mold 12 having a plurality of lower recessed grooves 12a having a checkerboard shape is fixed to the lower die 11 of the press. The upper die 13 of the press has a checkerboard shape as a lower surface. The upper plate mold (14) having a plurality of upper recessed grooves (14a) having a fixed structure, the press between the lower plate mold 12 and the upper plate mold 14, the sheet-like sheet 15 made of acrylic resin When the upper die 13 is moved downward, the upper plate mold 14 presses the plate-shaped sheet 15 made of the acrylic resin toward the lower plate mold 12, so that the lower recessed groove 12a formed on the upper surface of the lower plate mold 12. The sheet-shaped sheet 15 becomes the screen body 1 by the upper recessed groove 14a formed in the upper plate mold 14, and a plurality of front microlenses 2 having a checkerboard shape are formed on the screen body. A plurality of (3) are formed.

In this way, when the plurality of front microlenses 2 and the rear microlenses 3 are formed on the screen body 1, the screen body 1 is naturally cooled or cooled by using a separate cooler to produce a transmission type projection screen. Is complete.

However, the conventional transmission screen as described above does not block light incident to the rear microlens formed on the screen body of the light passing through the Fresnel lens when it is attached to the device as described above, so that the incident projection is inclined. As light is emitted as it is, the image formed by the inclined beam and the image formed by the parallel beam overlap with the front microlens, causing a decrease in resolution.

In addition, if the user operates the device while the fluorescent light or other light source is turned on in the room, the external light hits the front microlens of the screen body as it is and is reflected, which deteriorates the contrast of the image formed on the screen. It was a cause.

Meanwhile, in order to manufacture the conventional transmission type projection screen, a method of stamping a plate sheet with a press has been performed. For this purpose, a wide bottom recess groove should be formed in the bottom sheet metal shape of the press, and a wide bottom recess groove should be formed in the upper sheet metal shape. Therefore, there is a problem of increasing the production cost due to excessive expenditure of the mold manufacturing cost, as well as the problem that the productivity of the lower plate mold and the upper plate mold has to be limited.

The present invention has been made in order to solve the above problems, and when the structure of the front screen portion is used by changing the transmission type so that the resolution of the light passing through the Fresnel lens obliquely incident to the rear screen portion and the external light is blocked to increase the resolution. One purpose of providing a projection screen and a transmissive projection screen capable of mass production of a transmissive projection screen for blocking the incident light and external light incident to the rear screen portion so as to increase the resolution and at a low manufacturing cost. Another object of the present invention is to provide a method and apparatus for manufacturing the same.

According to the present invention for achieving the above object, a plurality of front microlenses protruding blocks while forming a checkerboard shape on the front screen portion of the screen body, and a plurality of rear surfaces protruding while forming a checkerboard shape on the rear screen portion of the screen body. Provided is a transmissive projection screen of the present invention comprising a microlens, a protruding piece formed at an interface of each front microlens, and a black film formed at an end of the protruding piece.

According to an aspect of the present invention for producing the above-described transmission type projection screen, the step of continuously discharging the molten resin in the form of a sheet; Forming a plurality of front microlenses so as to form a checkerboard on one surface of the sheet discharged by the process, and forming a protruding piece at the boundary of each front microlens; Cooling the screen body on which the rear microlens, the front microlens, and the protruding piece are formed by the above process; Provided is a method of manufacturing a transmissive projection screen of the present invention in which a process of giving a black film to the protruding end of the screen body cooled by the above process is sequentially performed.

According to the present invention for carrying out the method described above one side of the hopper for discharging the acrylic resin melted by the high temperature to the plate-like acrylic sheet, rotatably installed to the rear of the hopper is discharged to the plate from the hopper A lower roll mold for forming a plurality of rear microlenses in the form of a checkerboard, and a plurality of front microlenses in the form of a checkerboard are formed on the other side of the sheet discharged to the plate from the hopper and rotatably installed at the rear of the hopper. Along with the upper roll mold, which is formed behind the upper and lower roll molds to form a protruding piece to the warp surface of each front micro lens, a plurality of front micro lenses are formed on the sheet by the lower roll mold, A cooler that cools the screen body having a plurality of rear microlenses and protruding pieces formed on the sheet by the rear side of the cooling A plurality of guide rollers rotatably installed to guide the transfer of the screen body cooled by the cooler, and a printing roller rotatably installed at the rear of the cooler to apply a black film to the ends of the protruding pieces formed on the screen body. The present invention provides an apparatus for manufacturing a transmissive projection screen.

Hereinafter, the present invention will be described in more detail with reference to FIGS. 4 through 6 of the accompanying projection projection screen, and the manufacturing method of the present invention is described in more detail with reference to FIG. The apparatus for manufacturing a transmissive projection screen of the present invention will be described in more detail with reference to FIG. 8.

4 is a plan view showing a transmissive projection screen of the present invention, FIG. 5 is a cross-sectional view taken along line AA of FIG. 4, and FIG. 6 is a side view for explaining a state of use of the transmissive projection screen of the present invention. A plurality of front microlenses 2 protrudingly convex while forming a checkerboard shape are formed in the front screen part of (1), and a plurality of rear microprotrusions protruding while forming a checkerboard shape are formed in the rear screen part of the screen body 1. In the case where the lens 3 is formed, the protrusion pieces 4 are formed at the boundary surface of each front microlens 2, and the black film 5 is formed at the end of the protrusion pieces.

When the apparatus is operated while the present invention uses the transmissive projection screen configured as described above, the light projected by the enlarged projection lens (not shown) passes through the Fresnel lens and is incident on the transmissive projection screen to form an image.

That is, when light passing through the Fresnel lens is incident on the plurality of rear microlenses 3 formed on the rear surface of the screen body 1, the incident light is provided on the front surface of the screen body 1. Once collected and enlarged to one point of (2), an image is formed on the front microlens. At this time, the light passes through the Fresnel lens to the rear of the screen body 1 and the light incident to the microlens 3 in parallel (rear) Direction not perpendicular to the light lens) The incident light is not reflected but is tilted by a predetermined angle (θ) and is reflected by the protrusion 4 formed on the boundary surface of the front microlens 2, and then the black film coated on the end of the protrusion. It is removed by (5). In addition, when the user operates the apparatus while the fluorescent lamp or other light source is turned on in the room, the external light is removed by the black film 5 applied to the end of the protrusion 4.

Therefore, when the projection type transmission screen of the present invention is attached to the apparatus and used, the light incident to the rear microlens obliquely is blocked among the light passing through the Fresnel lens, so that the image due to the incident light in the inclined state is not formed on the front microlens. Of course, since the external light is also blocked, the external light is not reflected, so that the resolution is improved, thereby achieving a high quality screen.

In addition, Figure 7 is a flow chart for explaining the manufacturing process of the transmission type projection screen of the present invention, the method of the present invention is a step of continuously discharging the molten acrylic resin into a plate-like acrylic sheet, and discharged by the process A plurality of rear microlenses (3) are formed on one surface of the sheet-like acrylic sheet to form a checker board, and a plurality of front microlenses (2) are formed on the other surface to form a checkerboard shape. (4) forming, cooling the screen body (1) on which the rear microlenses (3), the front microlenses (2) and the protruding pieces (4) are formed by the steps; The process of applying the black film (5) to the end of the projecting piece (4) of the screen body (1) is cooled in order.

The process of discriminating between the goods manufactured by each process as good and defective goods may be included as a last process.

Although it will not be described in detail the process of manufacturing the transmissive projection screen of the present invention by each process of the present invention described above, it will be understood that referring to the description of the operation of the manufacturing apparatus described below.

8 is a front view schematically showing an apparatus for manufacturing a transmissive projection screen of the present invention, the apparatus of the present invention is a hopper 21 for discharging the acrylic resin melted by high temperature into a plate-like acrylic sheet, The lower part of the mold 22 and the back of the hopper 21 which are rotatably installed at the rear to form a plurality of checkered rear microlenses 3 on one surface of the sheet discharged into the plate from the hopper 21. The upper part which is rotatably installed and forms a plurality of checkered front microlenses 2 on the other surface of the sheet discharged into the plate from the hopper and forms a projection flat 4 at the boundary of each front microlens along with the zoom. It is installed at the rear of the roll mold 23 and the upper and lower roll molds, and a plurality of rear microlenses 3 are formed on the sheet by the lower ball mold 22 and a plurality of upper roll molds 23 are formed. A cooler 24 for cooling the screen body 1 formed on the sheet with the front microlenses 2 and the protruding piece 4 of the screen, and a screen body rotatably installed at the rear of the cooler to cool the screen body. 1) The black film 5 is applied to the end of the plurality of guide rollers 25 for guiding the conveyance and the end of the protruding piece 4 formed on the screen body 1 rotatably installed at the rear of the cooler 24. It consists of a printing roller 26 and a tester 27 installed at the rear of the printing roller to discriminate between good and bad goods.

In order to form the plurality of rear microlenses 3 on one surface of the sheet discharged into the plate from the hopper 21, the lower roll mold 22 is formed on the outer circumferential surface of the lower roll mold 22 The lower roll indenting groove 22a is formed, and the upper roll mold 23 forms a plurality of front microlenses 2 on the other surface of the sheet discharged from the hopper 21 into the plate shape, and the front microlenses respectively. A plurality of first upper roll indenting grooves 23a and second upper roll injecting grooves 23b are formed on the outer circumferential surfaces of the upper roll mold 23 so as to form the protruding flats 4 at the boundary surfaces of the lenses. .

Reference numeral 27a denotes a light emitting member constituting the inspector, 27b a light receiving member, and 27c a CCD camera.

Referring to the operation of the device of the present invention configured as described above is as follows.

The molten acrylic resin put into the hopper 21 is discharged from the hopper into a sheet form, and the discharged sheet sheet is rotated counterclockwise on the lower roll mold 22 that rotates clockwise in the drawing. In between the upper roll mold 23, a plurality of lower roll indentation grooves (22a) is formed on the outer circumferential surface of the lower roll mold 22, the plurality of first upper portion on the outer circumferential surface of the upper roll mold (23) Since the roll indenting groove 23a and the second upper roll inlet groove 23b are formed, the plate-like sheet becomes the screen body 1 and the plurality of front microlenses 2 having a checkerboard shape are continuously formed on one surface of the screen body. On the other side of the screen body 1, a plurality of rear microlenses 3 having a checkerboard shape are continuously formed, and a protruding piece 4 is formed at the boundary surface of each rear microlens.

In the above, the second upper and rear roll indenting grooves 23b formed on the outer circumferential surface of the upper roll mold 23 form a narrow inner side and a wide outer side, which are second upper roll indenting grooves 23 when the upper roll indenting grooves 23 rotate. This is because the projections 4 having the same shape as the shape of the mouth grooves 23b should be formed in the screen body 3 so that the rotation of the roll mold 23 and the transfer of the screen body 3 are performed smoothly.

Thus, the screen body 1, the lower roll mold 22 and the upper roll mold 23 in the state where the front microlens 2, the rear microlens 3 and the protruding piece 4 are formed on the screen body 1. Moved to the right side of the drawing while being guided to the plurality of guide rollers 25 by the rotational force of the rotational force, in which the end of the protruding piece 4 formed on the screen body 1 rotates the printing roller 26 Since the black ink impregnated on the printing roller is applied to the end of the protruding piece 4, the black film 5 is formed, thereby completing the manufacture of the transmissive projection screen.

The black ink impregnated in the printing roller 26 is applied only to the end of the protruding piece 4 formed on the screen body 1 and should not be applied to the front microlens 2. Since the height of the lens 2 must be higher than that of the upper roll mold 23, it is understood that the depth of the second upper roll indentation groove 23b formed in the outer circumferential surface of the upper roll mold 23 must be deeper than the depth of the first upper roll indentation groove 23a. Do.

On the other hand, even when the black film 5 is formed at the end of the protruding piece 4 formed on the screen body 1, the screen body 1 continues by the rotational force of the lower roll mold 22 and the upper roll mold 23. While passing to the right side passes the tester 27, the light emitting member 27a constituting the tester emits light so that the light emitted from the light emitting member is incident on the front microlens 2 formed on the screen body 1 and then the rear Projected through the microlenses 3 and the projected light is received by a single point on the light receiving member 27b constituting the inspector 27.

The size of one spot received by the light receiving member 27b is the thickness of the front microlenses 2 and the rear microlenses 3 formed on the screen body 1 or the black film 5 formed on the protruding pieces 4. Since the size of the dot is recognized by the CCD camera 27c by photographing and measured by the photographing, the good and defective parts of the projection type and the transmission screen may be screened out according to the measured data value.

Therefore, in the present invention, since the mold for forming the front microlens and the rear microlens on the screen body is a roll mold, the mold production cost can be drastically lowered than in the related art, so that the overall manufacturing cost of the apparatus is reduced, as well as the lower roll mold and the upper mold. Since the projection screen is continuously manufactured while the roll mold is rotating, productivity is also improved.

Claims (4)

Continuously discharging the molten resin in the form of a sheet; By forming a plurality of rear microlenses to form a checkerboard on one surface of the sheet discharged by the above process, and forming a plurality of front microlenses to form a checkerboard on the other surface while forming a protrusion on the boundary surface of each front microlens Giving process; Cooling the screen body on which the rear microlens, the front microlens and the protrusion 폄 are formed by the above process; The method of manufacturing a transmissive projection screen, characterized in that the step of applying a black film to the end of the protruding piece of the screen body cooled by the process is performed sequentially. A hopper for discharging the molten resin in a sheet form, a lower roll mold rotatably installed at a rear side of the hopper, and forming a plurality of checkerboard rear microlenses on one surface of the sheet discharged from the hopper; The upper roll mold which is rotatably installed at the rear of the hopper to form a plurality of checkerboard front microlenses on the other surface of the sheet discharged into the plate from the hopper to form a protrusion piece to the boundary surface of each front microlens along with the zoom And, installed on the rear of the upper and lower roll mold, the plurality of front microlenses are formed on the sheet by the lower roll mold and the plurality of rear microlenses and the protruding pieces are formed on the sheet by the lower roll mold to cool the screen body. The cooler is rotatably installed at the rear of the cooler to prevent the transfer of the screen body cooled by the cooler. A load-bearing apparatus for manufacturing a transmissive projection screen comprising a plurality of guide rollers and a printing roller rotatably installed to the rear of the cooler to apply a black film to the ends of the protruding pieces formed on the screen body. According to claim 3, wherein the lower roll mold to form a plurality of rear microlenses on the outer surface of the lower roll mold to form a plurality of rear microlenses on one surface of the sheet discharged from the hopper plate, the upper The outer mold surface of the upper roll mold to form a plurality of front microlenses on the other surface of the sheet discharged from the hopper to the plate form and to form protrusions on the boundary surface of each front microlens. An apparatus for manufacturing a transmissive projection screen, characterized by forming a plurality of first upper roll recess grooves and a second upper roll recess groove. The printing roller according to claim 3 or 4, wherein the second upper roll recess groove formed in the outer circumferential surface of the upper roll mold is formed deeper than the first upper roll recess groove so that the height of the protruding piece is higher than the height of the front microlens. Apparatus for manufacturing a transmissive projection screen characterized in that the impregnated black ink is applied only to the end of the protruding piece formed on the screen body.