Manufacturing method of optical projection screen

Abstract

A manufacturing method of an optical projection screen belongs to the technical field of optical projection, and comprises the following steps: S1, preparing a roller, and engraving a plurality of groove structures with inverted trapezoidal sections on the surface of the roller; s2, a first base material is prepared, the groove structure is transferred to one face of the first base material, and a plurality of protruding structures with trapezoidal sections are formed on the first base material; s3, preparing a mirror roller, and coating the top surface of the convex structure with a black light absorption material layer by using the mirror roller; and S4, manufacturing a reflective layer on the surface of the convex structure to obtain the optical projection screen. The problem that it is difficult to manufacture a black light absorption material layer on a part of tooth-shaped structures of an optical structure is solved, and the optical projection screen with the higher contrast ratio is manufactured.

Description

Technical Field

[0001] The invention belongs to the technical field of optical projection, and in particular relates to a method for manufacturing an optical projection screen. Background Art

[0002] With the development of projection technology, the image effects presented by projectors with optical diaphragms are becoming more and more exquisite, and they are loved by more and more consumers who pursue ultra-large screen effects. However, in order to achieve exquisite picture presentation effects, in addition to high-quality projectors, optical projection screens with good performance are essential. Today, as projector technology becomes more and more homogenized, the quality of the projection optical projection screen directly determines the perfection of the projection picture. The combination of the projector and the optical projection screen constitutes a complete projection display system. Generally, the higher the contrast of the projection system, the better. The contrast of the projection system is determined by the projector and the optical projection screen, but it is relatively more difficult to improve the contrast of the optical projection screen. This is because the optical projection screen is incident with both projector light and ambient light. To improve the contrast of the optical projection screen, it is necessary to eliminate as much ambient light as possible. Generally, a black light-absorbing material layer is set on the optical structure on the optical projection screen to absorb light, but this black light-absorbing material layer set at all positions on the optical structure will absorb both ambient light and projector light at the same time, so the contrast improvement is limited.

[0003] The present application proposes a feasible solution of setting a black light-absorbing material layer on the tooth-shaped structure of the optical structure on the optical projection screen where the projector light cannot be incident, so that the black light-absorbing material layer on the optical structure only absorbs ambient light, while the projection light is not absorbed, which can greatly improve the contrast of the optical projection screen. However, the optical structure of the prior art is generally a sawtooth structure, and the range of the projector light incident on the optical structure varies along different areas of the screen. Therefore, it is very difficult to make a black light-absorbing material layer only on the tooth-shaped structure of the sawtooth optical structure where the projector light cannot be incident. Therefore, those skilled in the art urgently need to solve the problem of difficulty in making a black light-absorbing material layer on the tooth-shaped structure of the optical structure where the projector light cannot be incident. Summary of the invention

[0004] The purpose of the present invention is to overcome the shortcomings of the prior art and provide a method for manufacturing an optical projection screen, which can effectively solve the problem of difficulty in manufacturing a black light-absorbing material layer on a part of the toothed structure of the optical structure, and manufacture an optical projection screen with higher contrast.

[0005] A method for manufacturing an optical projection screen of the present invention is achieved by the following technical solution:

[0006] A method for manufacturing an optical projection screen comprises the following steps:

[0007] S1. Prepare a roller, and carve a plurality of groove structures with inverted trapezoidal cross sections on the surface of the roller;

[0008] S2, preparing a first substrate, transferring the groove structure onto one side of the first substrate, and forming a plurality of protrusion structures with trapezoidal cross sections on the first substrate;

[0009] S3, preparing a mirror roller, and using the mirror roller to apply a black light-absorbing material layer on the top surface of the protruding structure;

[0010] S4, making a reflective layer on the surface of the protruding structure to obtain an optical projection screen.

[0011] The present application sets the optical structure on the optical projection screen into a trapezoidal raised structure. Through the positioning and limiting effect of the trapezoidal top surface, when a mirror roller is used to coat the raised structure with a black light-absorbing material layer, the black light-absorbing material can only be coated on the top surface of the raised structure, while there is no black light-absorbing material on the waist surface of the raised structure. In addition, one waist surface of the trapezoidal raised structure is set as the incident surface of the projector light, and the top surface cannot be incident with the projector light, but the ambient light can be incident on the top surface and absorbed. Therefore, the present method simply and easily achieves the purpose of making a black light-absorbing material layer only on that part of the tooth-shaped structure on which the projector light cannot be incident, thereby producing an optical projection screen with higher contrast, and effectively solving the problem of difficulty in making a black light-absorbing material layer on a part of the tooth-shaped structure of the optical structure.

[0012] Furthermore, before engraving a plurality of groove structures with inverted trapezoidal cross sections on the roller surface, the method further includes step S0 of determining the size of the groove structures at various positions on the roller surface, including the following sub-steps:

[0013] S01, setting the relative position relationship among the projector, the optical projection screen and the viewer, and the size of the optical projection screen;

[0014] S02, determining the bottom width and tooth height of each protruding structure according to the processing size range of the processing equipment, and presetting the top width and the angles between the two sides and the bottom of the protruding structure;

[0015] S03, simulating and calculating the distribution range of the projector's outgoing light incident on the waist surface and top surface of the convex structure on the optical projection screen;

[0016] S04, keeping the bottom width of the trapezoidal protruding structure unchanged, adjusting the top width and the angle between the two sides and the bottom of each protruding structure on the optical projection screen, so that the projector output light no longer impinges on the top surface of the protruding structure, and determining the top width and the angle between the two sides and the bottom of each protruding structure on the optical projection screen;

[0017] S05, distributing the trapezoidal protrusion structure parameters at each position on the optical projection screen to the roller surface accordingly, determining the size parameters of the groove structure on the roller surface, and inputting the groove structure size parameters and distribution range parameters into the engraving device for standby use.

[0018] Furthermore, in step S1, the method of engraving on the roller surface is laser ablation engraving or mechanical tool engraving.

[0019] Furthermore, in step S2, the groove structure is transferred to the first substrate by coating and pressing.

[0020] Furthermore, the roller is cylindrical, and the width of the top edge of each groove structure gradually decreases or increases from one end of the roller to the other opposite end; or the width of the top edge of each groove structure gradually decreases or increases along the circumference of the roller; one side of the first substrate is a rough surface, and the other opposite side is provided with a pigment or dye to facilitate the transfer of the groove structure to form a raised structure.

[0021] Furthermore, the method further comprises step S5 of bonding a side of the manufactured optical projection screen away from the reflective layer to a second substrate.

[0022] Furthermore, one side of the second substrate is a rough surface, and the other side opposite thereto is provided with a pigment or a dye and is bonded to the optical projection screen.

[0023] Furthermore, the black light-absorbing material is carbon black, copper chrome black, carbon, graphite, black iron oxide, aniline black dye or aniline black black dye; in step S4, the method of making the reflective layer is vacuum coating, spraying or printing.

[0024] Furthermore, the protruding structure is a non-isosceles trapezoid, and the angle between one waist and the base is 85° to 90°.

[0025] Furthermore, the roller in step S1 is conical, and the width of the top edge of the groove structure gradually increases from the small end of the roller to the opposite large end.

[0026] The beneficial effects of the present invention are:

[0027] The optical structure in the optical projection screen of the present application is a trapezoidal raised structure. Through the positioning and limiting effect of the trapezoidal top surface, a black light-absorbing material layer is coated on the top surface of the raised structure using a mirror roller. No black light-absorbing material layer is set on the waist surface of the raised structure, and one waist surface of the raised structure is set as the incident surface of the projector light. The top surface cannot be incident on the projector light, and the ambient light can be incident on the top surface and absorbed. Therefore, the present method is simple and easy to achieve the purpose of making a black light-absorbing material layer only on the part of the tooth-shaped structure on which the projector light cannot be incident, thereby producing an optical projection screen with a higher contrast, and effectively solving the problem of difficulty in making a black light-absorbing material layer on a part of the tooth-shaped structure of the optical structure. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 This is a schematic diagram of the groove structure engraved on the roller surface in the first embodiment of the present invention;

[0029] Figure 2 This is a schematic diagram of a protrusion structure made on a substrate according to the first embodiment of the present invention;

[0030] Figure 3 This is a schematic diagram of manufacturing a black light-absorbing material layer on a protruding structure according to the first embodiment of the present invention;

[0031] Figure 4 A schematic diagram of an optical projection screen with a reflective layer formed on a convex structure according to Embodiment 1 of the present invention;

[0032] Figure 5 A schematic diagram of another optical projection screen structure produced in accordance with the first embodiment of the present invention;

[0033] Figure 6 This is a schematic diagram of adjusting the size of the protruding structure to change the position of the projector light incident on the structure in accordance with the first embodiment of the present invention;

[0034] Figure 7 This is a schematic diagram of the change in the width of the top edge of the groove structure on the cylindrical roller according to the first embodiment of the present invention;

[0035] Figure 8 Schematic diagram of the change in the width of the top edge of the groove structure on the conical roller according to the first embodiment of the present invention;

[0036] Fig. 9 This is a schematic diagram of the structure of an optical projection screen manufactured according to the second embodiment of the present invention.

[0037] Explanation of the reference numerals: 10-roller; 20-mirror roller; 30-optical projection screen; 40-projector; 100-groove structure; 200-first substrate; 300-raised structure; 3001-top surface; 400-black light-absorbing material layer; 500-reflective layer; 600-second substrate; 700-rough surface; 800-pigment; 401-projected light; P-width of the top surface of the raised structure; α-angle between the waist surface with a larger inclination on the raised structure and the bottom edge; θ-angle between the waist surface with a smaller inclination on the raised structure and the bottom edge. DETAILED DESCRIPTION

[0038] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0039] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0040] Embodiment 1

[0041] Figure 1 This is a schematic diagram of the groove structure engraved on the roller surface in the first embodiment of the present invention; Figure 2 This is a schematic diagram of a protrusion structure made on a substrate according to the first embodiment of the present invention; Figure 3 This is a schematic diagram of manufacturing a black light-absorbing material layer on a protruding structure according to the first embodiment of the present invention; Figure 4 A schematic diagram of an optical projection screen with a reflective layer formed on a convex structure according to Embodiment 1 of the present invention; Figure 5 This is a schematic diagram of the structure of another optical projection screen manufactured according to the first embodiment of the present invention.

[0042] like Figures 1 to 5 As shown, a method for manufacturing an optical projection screen comprises the following steps:

[0043] S1. Prepare a roller, and engrave a plurality of groove structures 100 with inverted trapezoidal cross sections on the surface of the roller 10.

[0044] The shape of the roller 10 can be cylindrical or conical. Figure 1 In the middle figure a, the roller 10 is cylindrical, and the groove structure 100 engraved on the surface of the roller 10 is a linear shape parallel to the axial direction of the roller 10. Figure 1In the middle b figure, the roller 10 is cylindrical, and the groove structure 100 carved on the surface of the roller 10 is annular along the circumferential direction. In addition, the groove structure 100 carved on the surface of the roller 10 can also have a certain angle with the axial direction or the circumferential direction. The roller 10 is conical, and the groove structure 100 carved on the surface of the roller 10 can be annular along the circumferential direction, such as Figure 1 As shown in Figure c, it can also be a ring shape along the axial direction of the roller 10.

[0045] To further explain, the groove structure 100 with an inverted trapezoidal cross section can be engraved on the surface of the roller 10 by laser ablation or mechanical tool engraving. It can be engraved directly on the surface of the roller 10, or it can be engraved on the auxiliary material layer on the surface of the roller 10 after one or more auxiliary material layers are made on the surface of the roller 10 through a surface treatment process.

[0046] S2, such as Figure 2 As shown, a first substrate 200 is prepared, and the groove structure 100 on the surface of the roller 10 is transferred to one side of the first substrate 200, so as to form a plurality of protrusion structures 300 with a trapezoidal cross section on the first substrate 200;

[0047] To further explain, the material of the first substrate 200 can be at least one of the following materials, including but not limited to: polyethylene, polypropylene, polystyrene, polyvinyl chloride, cast polypropylene, biaxially oriented polypropylene film, polycarbonate, polyethylene terephthalate, polyamide, polyurethane, polymethyl methacrylate, polycarbonate, thermoplastic polyurethane elastomer rubber, glass, acrylic and ceramic. The first substrate 200 can be light-transmitting or opaque, and can be a hard flat plate or a flexible and rollable one. It can also be a multilayer board such as a carbon fiber board, a honeycomb board, an aluminum-plastic composite board, an iron-plastic composite board, etc.; it can also be cloth, leather, etc.

[0048] Furthermore, both surfaces of the first substrate 200 can be smooth surfaces, and the groove structure 100 on the surface of the roller 10 is transferred to any one surface to form a raised structure 300 with a trapezoidal cross-section; or one side of the first substrate 200 can be rough, and the other opposite side is provided with a pigment or dye, and the groove structure 100 on the surface of the roller 10 is transferred to the surface provided with the pigment or dye, and a raised structure 300 with a trapezoidal cross-section is produced on the first substrate 200.

[0049] Furthermore, if Figure 2As shown, the groove structure 100 on the surface of the roller 10 can be transferred by coating and embossing to form a convex structure 300 with a trapezoidal cross section on the first substrate 200. Specifically, the groove structure 100 with an inverted trapezoidal shape is filled by coating a resin material on the roller 10, the first substrate 200 partially wraps the surface of the roller 10, and the resin material is cured by ultraviolet light irradiation, heating, or radiation irradiation. At the same time, the first substrate 200 is moved by traction, and the roller 10 rotates, and the cured resin material is separated from the roller 10 together with the first substrate 200, so that the inverted trapezoidal groove structure 100 on the roller 10 is copied to the first substrate 200 to form a convex structure 300 with a trapezoidal cross section. The resin material can be a polyurethane resin or a polyester resin, which can be cured by radiation curing, heat curing, or reaction curing. In order to prevent the produced convex structure 300 from degradation, a hardener, an antistatic agent, a release agent, and an ultraviolet light absorber can also be added as additives. This method can realize roll-to-roll continuous production, greatly improving the production efficiency of optical microstructures.

[0050] As an optional method, the heated roller 10 may be pressed against the first substrate 200 , and after cooling, a protruding structure 300 with a trapezoidal cross section may be formed on the first substrate 200 .

[0051] Specifically, the heated high-temperature roller 10 is pressed against the first substrate 200 to melt a portion of the first substrate surface, and the molten substrate material is filled into the groove structure 100 on the roller 10. After the first substrate 200 is cooled, it is separated from the roller 10, so that the groove structure 100 on the roller 10 is replicated onto the first substrate 200 to form a raised structure 300 with a trapezoidal cross-section.

[0052] As an optional method, a convex structure 300 with a trapezoidal cross section can also be formed on the first substrate by casting and pressing a roller, a resin material and a first substrate. Specifically, a casting device is used to cast and composite the roller, the resin material and the first substrate. After the resin material is cured, a layer of convex structure with a trapezoidal cross section complementary to the inverted trapezoidal groove structure on the roller surface is formed between the roller and the first substrate. The convex structure with a trapezoidal cross section is separated from the roller together with the first substrate, that is, a convex structure 300 with a trapezoidal cross section is produced on the first substrate surface. The resin material can be a polyurethane resin or a polyester resin, which can be cured by radiation, heat or reaction. In order to prevent the degradation of the produced optical microstructure, a hardener, an antistatic agent, a release agent and an ultraviolet light absorber can also be added as additives.

[0053] S3, such as Figure 3 As shown, a mirror roller 20 is prepared, and a black light absorbing material layer 400 is coated on the top surface 3001 of the protruding structure on the first substrate 200 using the mirror roller;

[0054] To further explain, specifically, the black material and the resin material are uniformly mixed to make a liquid black light-absorbing resin material, the black light-absorbing resin material is coated using a mirror roller 20 on a coating machine, the surface of the mirror roller 20 is partially wrapped with a side of the first substrate having a raised structure 300 with a trapezoidal cross section, and the black light-absorbing resin material is cured by ultraviolet light irradiation, heating, or radiation irradiation, and at the same time, the first substrate 200 is moved by traction, and the roller rotates, and the cured black light-absorbing resin material is separated from the roller 10 together with the first substrate 200, that is, a black light-absorbing material layer 400 is produced only on the top surface 3001 of the raised structure 300 with a trapezoidal cross section. This method can realize roll-to-roll continuous production, is simple to implement, and can greatly improve the production efficiency of optical microstructures. In order to absorb more ambient light, the present application preferably sets the thickness of the black light absorbing material layer 400 to be greater than or equal to 500nm; since the material cost of a black light absorbing material layer that is too thick is too high, the present application preferably sets the thickness of the black light absorbing material layer 400 to be greater than or equal to 500nm and less than or equal to 300μm.

[0055] Furthermore, the black light-absorbing material 400 may be carbon black, copper chrome black, carbon, graphite, black iron oxide, aniline black dye or aniline black black dye; the resin material may be polyurethane resin or polyester resin, which may be cured by radiation or heat or reaction. In order to prevent the manufactured optical microstructure from degrading, a hardener, an antistatic agent, a release agent, and an ultraviolet light absorber may be added as additives.

[0056] S4, such as Figure 4 As shown, a reflective layer 500 is made on the protruding structure 300 on the first substrate 200 to form an optical projection screen.

[0057] To further explain, the method of manufacturing the reflective layer 500 may be vacuum coating, spraying or printing.

[0058] Furthermore, a reflective layer 500 is uniformly plated on the surface of the protruding structure 300 on the first substrate 200 using a vacuum coating device. The reflective layer 500 is used to enhance the ability of the optical projection screen to reflect projection light, reduce the projection light passing through the optical projection screen, and improve the brightness gain and contrast of the optical projection screen. The material of the reflective layer 500 can be a metal material such as aluminum, copper, gold, or a combination of non-metallic materials with high and low refractive indices, such as SiO2 and Al2O3, Sio2 and Ta2O5, etc. The reflectivity of the reflective layer can be adjusted by controlling the thickness of the reflective layer to balance the brightness gain of the optical projection screen. Because when the thickness of the reflective layer is large, the reflectivity is high, and the brightness gain of the optical projection screen is also high; when the thickness of the reflective layer is small, the reflectivity is low, and the brightness gain of the optical projection screen is also low. The technical solution of the present invention preferably has a reflective layer made of a metal material, and the thickness of the reflective layer ranges from 40nm to 200nm, so that it can have a sufficient reflective effect.

[0059] Furthermore, the reflective layer 500 is manufactured by spraying or printing. Specifically, ink or coating containing reflective material is prepared, and the ink or coating is made on the surface of the trapezoidal protrusion structure by using printing equipment or spraying equipment.

[0060] Furthermore, if Figure 4 As shown, after the reflective layer is manufactured, an optical projection screen including a first substrate 200, a protruding structure 300, a black light-absorbing material layer 400 disposed on the top surface of the protruding structure, and a reflective layer 500 disposed on each surface of the protruding structure is manufactured. In the present application, the optical structure on the optical projection screen is set to be a trapezoid. Through the positioning and limiting effect of the top surface of the protruding structure, when the black light-absorbing material layer is coated on the protruding structure using a mirror roller, the black light-absorbing material can only be coated on the top surface of the protruding structure, while there is no black light-absorbing material on the waist surface of the protruding structure. In addition, one waist surface of the protruding structure is set as the incident surface of the projector light, and the top surface cannot be incident with the projector light, but the ambient light can be incident on the top surface and absorbed. Therefore, the present method is simple and easy to implement and realizes the purpose of manufacturing the black light-absorbing material layer only on the part of the tooth-shaped structure on which the projector light cannot be incident, thereby manufacturing an optical projection screen with higher contrast, and effectively solving the problem of difficulty in manufacturing the black light-absorbing material layer on a part of the tooth-shaped structure of the optical structure.

[0061] Furthermore, if Figure 5The optical projection screen shown includes a first substrate 200, the surface of the first substrate 200 is a rough surface 700, a pigment 800 or a dye is arranged on the side of the first substrate 200 opposite to the rough surface, a plurality of protruding structures 300 are made on the side of the first substrate 200 away from the rough surface 700, a black light absorbing material layer 400 is arranged on the top surface of the protruding structure 300, and a reflective layer 500 is arranged on each surface of the protruding structure. The rough surface 700 can effectively diffuse the incident light of the projector, thereby increasing the viewing field.

[0062] Figure 6 This is a schematic diagram of adjusting the size of the protruding structure to change the position of the projector light incident on the structure in accordance with the first embodiment of the present invention.

[0063] Before engraving a plurality of groove structures with inverted trapezoidal cross sections on the roller surface, the method further includes: step S0, determining the size of the groove structures at various positions on the roller surface, including the following sub-steps:

[0064] S01, setting the relative position relationship among the projector, the optical projection screen and the viewer, and the size of the optical projection screen;

[0065] To further explain, the position of the projector and the optical projection screen is divided into the horizontal distance and vertical distance between the projector and the optical projection screen. The horizontal distance can be characterized by the projection ratio, and the vertical distance can be characterized by the eccentricity. The horizontal distance and vertical distance uniquely determine the position of the projector and can also determine the incident angle range of the projection light. The position of the viewer is divided into the distance between the viewer and the optical projection screen and the horizontal field of view of the viewer, which together determine the direction of the image light emitted after being reflected by the raised structure. Therefore, the projector, the optical projection screen and the viewer jointly determine the angle range between the surface of the projected light reflected by the raised structure on the optical projection screen and the screen surface of the optical projection screen, as well as the size range of the surface reflecting the projection light. Therefore, the relative positions of the projector, the optical projection screen and the viewer and the size of the optical projection screen can determine the position of the projector light incident on the optical projection screen, as well as the range of the light emitted by the optical projection screen, so that it can be seen by the viewer.

[0066] S02. Determine the bottom width and tooth height of each protruding structure according to the processing size range of the processing equipment, and preset the top width of the protruding structure and the angles between the two sides and the bottom;

[0067] Further explanation: the processing equipment determines the characteristics of the tooth shape that can be processed, the tooth shape depth, and the range of widths of each side of the tooth shape. Therefore, when designing and processing the tooth shape, the range that the equipment can process should be used as the basis to avoid the designed tooth shape that the equipment cannot process. Since the specific shape of the tooth shape of the raised structure cannot be determined at present, the bottom width and tooth height of the trapezoidal raised structure can be determined first, and the variables can be controlled. Then, a certain top width and the angles between the two waists and the bottom can be preset, so as to construct the shape and position arrangement of the optical structure tooth shape on the optical projection screen, and form a preliminary design result.

[0068] As a further supplementary explanation, the bottom width of the raised structure directly affects the processing difficulty and the image display resolution effect of the optical projection screen. Generally, the smaller the width, the better the resolution effect of the optical projection screen, but the higher the processing difficulty. Therefore, the design should ensure both the image resolution effect and the processing difficulty. Therefore, the bottom edge of the raised structure is preferably 50μm to 200μm. The tooth height of the raised structure refers to the vertical distance between the top surface of the raised structure and the bottom surface of the tooth. In this embodiment, the tooth height of the raised structure is preferably 40μm to 100μm.

[0069] S03, simulating and calculating the distribution range of the projector's outgoing light incident on the waist surface and top surface of the convex structure on the optical projection screen;

[0070] Further explanation: Based on the preliminary design results, we can simulate the distribution range of the projection light incident on the protruding structures on the optical projection screen. There are two results: Figure 6 As shown in FIG. B, first, the parameters of the designed protruding structure 300 just meet the requirements, and the projection light 401 is incident only on one waist surface of the protruding structure 300, and not on the top surface 3001. At this time, there is no need to adjust the tooth profile parameters. Of course, the tooth profile can also be adjusted to obtain a better design; Figure 6 As shown in Figure A, another result is that the projection light 401 is incident on the waist surface and top surface 3001 of the trapezoidal protrusion structure 300, and the designed tooth profile parameters do not meet the requirements. Then the next step of adjustment is required.

[0071] S04, such as Figure 6 As shown in FIG. A, the bottom width of the protruding structure 300 is kept unchanged, and the top width P of the protruding structure at each position on the optical projection screen 30 and the angles between the two waists and the bottom are adjusted. The angle between the waist with a larger inclination on the protruding structure and the bottom edge is recorded as α, and the angle between the waist with a smaller inclination on the protruding structure and the bottom edge is recorded as θ, so that the light 401 emitted by the projector 40 no longer impinges on the top surface 3001 of the protruding structure, as shown in FIG. Figure 6As shown in Figure B, the width P of the top surface 3001 of the protruding structure 300 at each position on the optical projection screen 30 and the angles α and θ between the two sides and the bottom surface are determined, and combined with the bottom edge width and tooth height parameters of the protruding structure determined in the previous steps, the processing parameters of the protruding structure can be completely determined.

[0072] S05, distributing the protrusion structure parameters at each position on the optical projection screen to the roller surface accordingly, determining the size parameters of the groove structure on the roller surface, and inputting the groove structure size parameters and distribution range parameters into the engraving device for standby use.

[0073] To further explain, it can be known that the raised structure on the optical projection screen and the groove structure on the roller are complementary to each other. Therefore, the shape parameters of the raised structure on the designed optical projection screen can be easily converted into the shape parameters of the groove structure on the roller, thereby determining the processing parameters of the groove structure on the roller. At this time, the processing parameters are input according to the equipment requirements and the groove structure can be processed on the roller after the roller is prepared.

[0074] Furthermore, if Figure 6 As shown in Figure B, the raised structure is set as a non-isosceles trapezoid, and the angle θ between one waist of the raised structure 300 and the bottom edge is 85° to 90°. The waist on the trapezoidal raised structure 300 is close to the projector 40, and θ is set to 85° to 90°, which can be more easily adjusted so that the projection light 401 does not impinge on the waist surface, and then does not impinge on the top surface 3001 of the raised structure, reducing the variables that need to be adjusted for the tooth profile parameters, and combined with the setting of the non-isosceles trapezoid, it is only necessary to adjust the size of the top surface width P of the raised structure of the non-isosceles trapezoid at each position on the optical projection screen 30, so that the projection light 401 is only incident on the waist surface of the non-isosceles trapezoid away from the projector 40, and not on the top surface 3001 of the non-isosceles trapezoid and the waist surface close to the projector 40.

[0075] Furthermore, the present application sets the raised structure (optical structure) on the optical projection screen into a non-isosceles trapezoid, and adjusts the top surface width of the non-isosceles trapezoid corresponding to each position according to the different positions of the projection light incident on the non-isosceles trapezoid at each position on the optical projection screen, so that the projection light is further incident on the waist surface of the non-isosceles trapezoid away from the projector. Through the reflection effect of the waist surface on the projection light, the projection light is incident on the viewer area after passing through the optical projection screen, while the ambient light incident on the optical projection screen from other directions can be incident on the top surface of the non-isosceles trapezoid and absorbed by the black light-absorbing material, thereby producing an optical projection screen with higher contrast.

[0076] Figure 7 Schematic diagram of the variation of the top width of the groove structure on a cylindrical roller in accordance with an embodiment of the present invention. The roller 10 in step S1 is set to be cylindrical, such as Figure 7As shown by the double arrows in Figure a, the top width p of the inverted trapezoidal groove structure 100 gradually increases from one end of the roller to the other end; or the top width p of the inverted trapezoidal groove structure 100 gradually decreases from one end of the roller to the other end; Figure 7 As shown by the arc double arrows in Figure b, the top edge width p of the inverted trapezoidal groove structure 100 gradually decreases along the circumference of the roller; or the top edge width p of the inverted trapezoidal groove structure 100 gradually increases along the circumference of the cylindrical roller.

[0077] Figure 8 Schematic diagram of the change in the top width of the groove structure on the conical roller in the first embodiment of the present invention. The roller 10 in step S1 can be set to be conical, such as Figure 8 As shown by the single arrow in the middle, the top edge width p of the inverted trapezoidal groove structure 100 gradually increases from the small end of the roller to the opposite large end. When the roller is conical, when the groove structure 100 is arranged in an annular manner along the conical surface, a strip-shaped trapezoidal convex structure arranged in an annular manner is formed after being coated on the first substrate by the conical roller; and when the groove structure is arranged along the axial direction of the cone, a divergent strip-shaped trapezoidal convex structure is formed after being coated on the first substrate by the roller.

[0078] To further explain, the top edge width of the groove structure is set to change in one direction, so that the top edge width P of the protruding structure with a complementary shape also changes in one direction, thereby matching the position of light incident on the protruding structure by the projector, making the design and production of the optical projection screen simpler.

[0079] Furthermore, the mirror roller 20 in step S3 can be set to a cylindrical shape or a conical shape. It can be seen that the roller surface of the mirror roller 20 is smooth and flat, which can better control the amount of black light-absorbing material on the top surface of the trapezoidal protrusion structure, thereby reducing material waste and controlling costs.

[0080] Embodiment 2

[0081] Fig. 9 This is a schematic diagram of the structure of an optical projection screen manufactured according to the second embodiment of the present invention.

[0082] The difference between the optical projection screen produced in this embodiment and the embodiment 1 is that the produced optical projection screen further comprises step S5, bonding the side of the optical projection screen produced in step S4 in the embodiment 1 away from the reflective layer 500 to the second substrate 600 to produce an optical projection screen of another structure.

[0083] Specifically, the surface of the second substrate 600 is a rough surface 700, and the other opposite side is provided with a pigment 800, and is bonded to an optical projection screen comprising a first substrate 200, a protruding structure 300, a black light-absorbing material layer 400 disposed on the top surface of the protruding structure, and a reflective layer 500 disposed on each surface of the protruding structure to form another structure of a light projection screen. The rough surface 700 can effectively diffuse the light incident from the projector, thereby increasing the viewing field. Of course, functional layers such as a diffusion layer, a microstructure layer, a polarization layer, and a selective absorption layer can also be provided on the optical projection screen to achieve different optical effects, which will not be listed one by one here.

[0084] Those skilled in the art will appreciate that the embodiments described herein are intended to help readers understand the principles of the present invention, and should be understood that the protection scope of the present invention is not limited to such specific statements and embodiments. Those skilled in the art can make various other specific variations and combinations that do not deviate from the essence of the present invention based on the technical revelations disclosed by the present invention, and these variations and combinations are still within the protection scope of the present invention.

Claims

1. A method for manufacturing an optical projection screen, characterized in that: The following steps are involved: S1. Prepare a roller, and carve a plurality of groove structures with inverted trapezoidal cross sections on the surface of the roller; S2, preparing a first substrate, transferring the groove structure onto one side of the first substrate, and forming a plurality of protrusion structures with trapezoidal cross sections on the first substrate; S3, preparing a mirror roller, and using the mirror roller to apply a black light-absorbing material layer on the top surface of the protruding structure; S4, making a reflective layer on the surface of the protruding structure to obtain an optical projection screen.

2. The method according to claim 1, characterized in that: Before engraving a plurality of groove structures with inverted trapezoidal cross sections on the roller surface, the method further includes: step S0, determining the size of the groove structure at each position on the roller surface, including the following sub-steps: S01, setting the relative position relationship among the projector, the optical projection screen and the viewer, and the size of the optical projection screen; S02, determining the bottom width and tooth height of each protruding structure according to the processing size range of the processing equipment, and presetting the top width and the angles between the two sides and the bottom of the protruding structure; S03, simulating and calculating the distribution range of the projector's outgoing light incident on the waist surface and top surface of the convex structure on the optical projection screen; S04, keeping the bottom width of the protruding structure unchanged, adjusting the top width and the angle between the two waists and the bottom of each protruding structure on the optical projection screen, so that the projector output light no longer impinges on the top surface of the protruding structure, and determining the top width and the angle between the two waists and the bottom of each protruding structure on the optical projection screen; S05, distributing the protrusion structure parameters at each position on the optical projection screen to the roller surface accordingly, determining the size parameters of the groove structure on the roller surface, and inputting the groove structure size parameters and distribution range parameters into the engraving device for standby use.

3. The method according to claim 1, characterized in that: In step S1, the method of engraving on the roller surface is laser ablation engraving or mechanical tool engraving.

4. The method according to claim 1, characterized in that: In step S2, the groove structure is transferred to the first substrate by coating and pressing.

5. The method according to claim 1, characterized in that: The roller is cylindrical, and the width of the top edge of each groove structure gradually decreases or increases from one end of the roller to the other opposite end; or the width of the top edge of each groove structure gradually decreases or increases along the circumference of the roller; one side of the first substrate is a rough surface, and the other opposite side is provided with a pigment or dye to facilitate the transfer of the groove structure to form a raised structure.

6. The method according to claim 1, characterized in that: The method further comprises step S5 of bonding the side of the manufactured optical projection screen away from the light reflecting layer to the second substrate.

7. The manufacturing method according to claim 6, characterized in that: One side of the second substrate is a rough surface, and the other side opposite to the second substrate is provided with a pigment or a dye and is bonded to the optical projection screen.

8. The manufacturing method according to claim 1, characterized in that: The black light-absorbing material is carbon black, copper chrome black, carbon, graphite, black iron oxide, aniline black dye or aniline black black dye; in step S4, the method of making the reflective layer is vacuum coating, spraying or printing.

9. The manufacturing method according to claim 1, characterized in that: The protruding structure is a non-isosceles trapezoid, and the angle between one waist and the bottom edge is 85° to 90°.

10. The manufacturing method according to claim 1, characterized in that: The roller in step S1 is conical, and the width of the top edge of the groove structure gradually increases from the small end of the roller to the opposite large end.

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