Projection screen, manufacturing method thereof and projection system

Abstract

A projection screen (1) includes a surface layer (11), a Fresnel structure layer (12), a reflective layer (13), and an adhesive layer (14), the adhesive layer (14) adheres the surface layer (11) to the Fresnel structure layer (12) on which the reflective layer (13) is formed, and a Fresnel structure (f) is disposed facing a side of the surface layer (11). The bonding layer (14) directly bonds the surface layer (11) and the reflecting layer (13), and a protective layer does not need to be arranged on the reflecting layer (13). The invention further provides a manufacturing method of the projection screen (1) and a projection system.

Description

Projection screen, manufacturing method thereof and projection system

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to the Chinese patent application filed with the China Patent Office on October 17, 2022, with application number 202211265387.4, and invention name “Projection screen, its manufacturing method and projection system”, the entire contents of which are incorporated by reference into this application. Technical Field

[0003] The present application relates to the field of projection technology, and in particular to a projection screen, a manufacturing method thereof, and a projection system. Background Art

[0004] With the increasing popularity of laser display products, the market for large-screen laser TVs, a viable alternative to LCD and OLED TVs, is rapidly expanding. To achieve optimal brightness and display quality, projection equipment is typically used in conjunction with a projection screen. Compared to projecting images onto a white wall, projection screens offer higher gain, wider viewing angles, and suppress reflections of external light, resulting in superior contrast.

[0005] In current front-projection systems, projection light is emitted by the projection device and incident on the projection screen. After being reflected by the screen, the reflected light is reflected forward, resulting in the projected image being viewed. The Fresnel reflective structure in the projection screen serves to reflect the projection light toward the viewer. This Fresnel reflective structure is typically achieved by forming a reflective layer on the surface of the Fresnel structure. A commonly used reflective material is aluminum paste, which is applied to the Fresnel structure via a wet coating process. However, this method does not guarantee the designed reflection angle of the aluminum paste surface, so the Fresnel structure side must be the light-entering side. To overcome the issues associated with aluminum paste, a metal film can also be vapor-deposited on the surface of the Fresnel structure. However, to prevent the metal film from being scratched or peeled off, a protective layer must be applied to the metal film, resulting in complex processes and high costs.

[0006] Summary of the Invention

[0007] According to a first aspect of an embodiment of the present application, a projection screen is provided, comprising:

[0008] surface layer;

[0009] A Fresnel structure layer is located on one side of the surface layer, and a Fresnel structure is provided on a surface of the Fresnel structure layer facing the surface layer;

[0010] a reflective layer, located on a surface of the Fresnel structure layer facing the surface layer, wherein the reflective layer has a uniform thickness; and

[0011] An adhesive layer is located between the surface layer and the reflective layer, and is used to bond the surface layer to a surface of the Fresnel structure layer on which the reflective layer is provided.

[0012] According to a second aspect of the present application, a projection system is provided, comprising:

[0013] Projection equipment, used for emitting projection light; and

[0014] The projection screen is located on the light-emitting side of the projection device, and the projection screen is any of the above-mentioned projection screens.

[0015] According to a third aspect of the embodiments of the present application, a method for manufacturing a projection screen is provided, comprising:

[0016] a surface treatment step of providing a substrate and performing surface treatment on the substrate to obtain a surface layer;

[0017] A Fresnel structure manufacturing step, manufacturing a Fresnel structure layer, and forming a reflective layer on the Fresnel structure surface of the Fresnel structure layer; and

[0018] In the bonding step, the surface layer and the surface of the Fresnel structure layer on which the reflective layer is formed are bonded to each other using an adhesive layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following is a brief introduction to the drawings required for use in the embodiments of the present application. Obviously, the drawings introduced below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0020] FIG1 is a schematic structural diagram of a projection system provided in an embodiment of the present application;

[0021] FIG2 is a schematic diagram of a manufacturing process of a Fresnel reflection structure in the related art;

[0022] FIG3 is a second schematic diagram of the manufacturing process of the Fresnel reflection structure in the related art;

[0023] FIG4 is a schematic diagram of light reflection by a Fresnel reflection structure in the related art;

[0024] FIG5 is a schematic structural diagram of a Fresnel reflection structure in the related art;

[0025] FIG6 is a schematic diagram of a structure of a projection screen according to an embodiment of the present application;

[0026] FIG7 is a schematic diagram of one of the manufacturing processes of the Fresnel structure layer provided in an embodiment of the present application;

[0027] FIG8 is a second structural diagram of a projection screen provided in an embodiment of the present application;

[0028] FIG9 is a third structural diagram of a projection screen provided in an embodiment of the present application;

[0029] FIG10 is a second schematic diagram of the manufacturing process of the Fresnel structure layer provided in an embodiment of the present application;

[0030] FIG11 is a fourth structural diagram of a projection screen provided in an embodiment of the present application;

[0031] FIG12 is a fifth structural diagram of a projection screen provided in an embodiment of the present application;

[0032] FIG13 is a sixth structural diagram of a projection screen provided in an embodiment of the present application;

[0033] FIG14 is a seventh structural diagram of a projection screen provided in an embodiment of the present application;

[0034] FIG15 is an eighth structural diagram of a projection screen provided in an embodiment of the present application;

[0035] FIG16 is a ninth structural diagram of a projection screen provided in an embodiment of the present application;

[0036] FIG17 is a tenth structural diagram of a projection screen provided in an embodiment of the present application;

[0037] FIG18 is an eleventh structural diagram of a projection screen provided in an embodiment of the present application;

[0038] FIG19 is a schematic diagram of the structure of a projection device provided in an embodiment of the present application;

[0039] FIG20 is a flowchart of a method for manufacturing a projection screen according to an embodiment of the present application;

[0040] FIG21 is a second flowchart of the method for manufacturing a projection screen provided in an embodiment of the present application;

[0041] FIG22 is a schematic diagram of one of the production processes of a projection screen according to an embodiment of the present application;

[0042] FIG23 is a second schematic diagram of the production process of a projection screen provided in an embodiment of the present application;

[0043] FIG24 is a third schematic diagram of the production process of a projection screen provided in an embodiment of the present application;

[0044] FIG25 is a fourth schematic diagram of the production process of the projection screen provided in an embodiment of the present application.

[0045] Among them, 1-projection screen, 2-projection equipment, f-Fresnel structure, Re'-aluminum paste, Re, 13-reflective layer, Re1-metal film, c-protective layer, 11-surface layer, 12-Fresnel structure layer, 14-adhesive layer, 111-second substrate, 112-diffusion layer, 121-first substrate, 21-light source device, 22-illumination optical path, 23-light modulation component, 24-projection lens, f'-ultraviolet curing resin, 12'-thermoplastic material layer, M-mold, s1, s2-separation layer, J1-first volume, J2-second volume, J3-third volume, J4-fourth volume, J5-fifth volume. DETAILED DESCRIPTION

[0046] In order to make the objectives, technical solutions and advantages of the embodiments of the present application clearer, the implementation methods of the present application will be further described in detail below with reference to the accompanying drawings.

[0047] With the increasing popularity of laser display products, the market for laser TVs is rapidly expanding as a large-screen alternative to LCD and OLED TVs. To achieve optimal brightness and display quality, projection equipment is typically used in conjunction with a projection screen. Compared to projecting images onto a white wall, projection screens offer higher gain, a wider viewing angle, and suppress reflections of external light, resulting in superior contrast.

[0048] FIG1 is a schematic structural diagram of a projection system provided in an embodiment of the present application.

[0049] As shown in FIG1 , the projection system includes a projection device 2 and a projection screen 1 .

[0050] The projection screen 1 is located on the light-emitting side of the projection device 2. The audience faces the projection screen 1. The projection device 2 emits projection light, which is incident on the projection screen 1, reflected by the projection screen 1 and reflected forward, so that the audience can see the projected image.

[0051] Ultra-short-throw laser projection equipment has the characteristics of small projection distance and large projection image, which is very suitable for home use. In order to achieve better brightness and display effects, it needs to be used with a projection screen.

[0052] Current front-projection systems use a projection device to emit light, which then strikes a projection screen. The light is then reflected forward by the screen, allowing the projected image to be viewed. The projection screen incorporates a Fresnel reflector structure that reflects the light.

[0053] FIG. 2 is a schematic diagram of the manufacturing process of the Fresnel reflection structure in the related art; FIG. 3 is a schematic diagram of the manufacturing process of the Fresnel reflection structure in the related art.

[0054] As shown in FIG2 , currently, the Fresnel reflective structure is usually formed by wet-coating the surface of the Fresnel structure f with aluminum paste Re'. The aluminum paste Re' contains not only aluminum powder and resin but also a solvent. Therefore, after the aluminum paste Re' is wet-coated on the surface of the Fresnel structure f, it needs to be dried. After the drying process, a concave-convex reflective layer Re is formed in which the Fresnel valleys are filled, as shown in FIG3 .

[0055] FIG4 is a schematic diagram of light reflection by a Fresnel reflection structure in the related art.

[0056] As shown in Figure 4, when a reflective layer is made using wet-coated aluminum paste, the surface of the dried reflective layer Re only has the rough outline of the Fresnel structure and cannot maintain the same angle as the Fresnel structure. The surface angle of the Fresnel structure is specifically designed based on the incident angle of the projection light during projection. As shown in Figure 4 (a), after the projection light enters the Fresnel structure f, it can be reflected in the forward direction. However, if the reflective layer Re formed using wet-coated aluminum paste is used as the light-entering side, as shown in Figure 4 (b), the reflective layer Re cannot maintain the surface angle of the Fresnel structure f. As a result, the projection light cannot be reflected in the ideal direction when it enters the reflective layer Re, causing the reflected light to deviate from the direction. As a result, viewers directly in front of the projection screen will not receive sufficient reflected light, affecting the display quality.

[0057] Therefore, as shown in Figure 4, when wet-coating aluminum paste to form the reflective layer Re, the light-entering side of the Fresnel structure f must be the side facing the light, not the side facing the reflective layer Re. This requires the Fresnel structure f to be made of optical materials with better light transmittance and higher processing precision, resulting in higher costs.

[0058] In order to overcome the problems caused by the use of aluminum paste, a metal film can also be evaporated on the surface of the Fresnel structure. Figure 5 is a schematic diagram of the structure of a Fresnel reflection structure in the related art.

[0059] As shown in FIG5 , a metal film layer Re1 is evaporated on the surface of the Fresnel structure f to serve as a reflective layer. However, in order to prevent the metal film Re1 from being scratched or peeled off, a protective layer c is also required to be provided on the surface of the metal film Re1. The protective layer c can usually be formed by the wet coating method mentioned above, which will lead to problems such as complex process and high cost of the projection screen.

[0060] In view of this, an embodiment of the present application provides a projection screen that can reduce the number of manufacturing processes and lower costs while ensuring good optical performance.

[0061] FIG6 is one of the structural schematic diagrams of the projection screen provided in an embodiment of the present application.

[0062] As shown in FIG6 , the projection screen provided in the embodiment of the present application includes: a surface layer 11 , a Fresnel structure layer 12 , a reflective layer 13 and an adhesive layer 14 .

[0063] The surface layer 11 is located on one side (the outermost side) of the projection screen and is the film layer that directly faces the audience. In the embodiment of the present application, the side of the surface layer 11 facing the audience may also be surface treated to achieve effects such as expanding the viewing angle, resisting ambient light reflection, and resisting ceiling reflection.

[0064] The Fresnel structure layer 12 is located on the other side of the projection screen, specifically on the side of the surface layer 11 facing away from the viewer. A Fresnel structure f is provided on the surface of the Fresnel structure layer 12 facing the surface layer 11. The Fresnel structure f has an inclined surface, the angle of which is designed to reflect projection light incident on the projection screen toward the viewer. In practice, the Fresnel structure f can be arranged in concentric circles or in a periodic checkerboard pattern, without limitation.

[0065] The reflective layer 13 is located on the surface of the Fresnel structure layer 12 that faces the surface layer 11, with the surface of the reflective layer 13 facing the surface layer 11 serving as the reflective surface. In the embodiment of the present application, the reflective layer 13 is a metal film formed by evaporation or sputtering. The metal film covers the surface of the Fresnel structure f and has a uniform thickness. The surface of the metal film has the same undulating trend as the Fresnel structure, and the surface of the metal film can maintain the designed reflection angle of the Fresnel structure for incident light.

[0066] In a preferred embodiment, the metal film can be made of metals such as aluminum, silver, and titanium, which are not limited here.

[0067] The adhesive layer 14 is located between the surface layer 11 and the reflective layer 13. The adhesive layer 14 is used to bond the surface layer 11 and the surface of the Fresnel structure layer 12 on which the reflective layer 13 is disposed.

[0068] When the Fresnel structure f is facing the side of the surface layer 11, the surface layer 11 and the Fresnel structure layer 12 formed with the reflective layer 13 are bonded by the adhesive layer 14. In this way, the surface layer 11 and the reflective layer 13 can be directly bonded using the adhesive layer 14, and there is no need to set a protective layer on the reflective layer 13, which simplifies the process flow and reduces costs.

[0069] The side of the reflective layer 13 covering the Fresnel structure f facing the surface layer 11 is used as the reflective surface, as shown in Figure 6. Projection light does not need to first pass through the Fresnel structure layer before being reflected. Instead, it is directly incident on the reflective layer on the surface of the Fresnel structure and reflected. This reduces the number of film layers that projection light passes through during its reflection from the projection screen, reducing light loss caused by reflection at the interfaces of the film layers and absorption by the film layers. More light can be reflected forward, thereby increasing gain.

[0070] Since the Fresnel structure layer 12 is located on the side farthest from the audience and no light enters the Fresnel structure layer 12 , the requirements on the light transmittance and damage specifications of the Fresnel structure layer 12 are reduced. It is no longer necessary to use expensive optical materials to make the Fresnel structure layer 12 , and cheaper industrial materials can be used for production, thereby reducing production costs.

[0071] In a preferred embodiment, pressure sensitive adhesive (PSA), ultraviolet curable resin or two-component curable resin can be used to make the adhesive layer 14. In addition, other adhesive materials can also be used to make the adhesive layer 14, which is not limited here.

[0072] In some embodiments, as shown in Figure 6, the Fresnel structure layer 12 includes a first substrate 121, and the surface of the first substrate 121 facing the surface layer 11 and the surface opposite to the surface layer 11 are both flat surfaces, and the Fresnel structure f is located on the surface of the first substrate 121 facing the surface layer 11.

[0073] Among them, the first substrate 121 can be made of relatively cheap industrial materials. For example, the first substrate 121 can be made of materials such as polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polycarbonate (PC), polymethyl methacrylate (PMMA), triacetylcellulose (TAC), cycloolefin polymer (COP), thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), polyimide (PI), polyamide (PA), polyethylene (PE), and polypropylene (PP).

[0074] The Fresnel structure f can be manufactured by using a mold M having a Fresnel structure and a UV molding process using an ultraviolet curable resin. FIG7 is a schematic diagram of one of the manufacturing processes of the Fresnel structure layer provided in an embodiment of the present application.

[0075] For example, the Fresnel structure f can be formed by applying a UV-curable resin to a mold M having a Fresnel structure, then embossing and UV-curing the UV-curable resin using a first substrate. As shown in Figure 7, UV-curable resin f' is first applied to the mold M having the Fresnel structure on its surface. Next, UV-curable resin f' is embossed onto the first substrate 121 with a predetermined pressure, and UV light is applied from the side of the first substrate 121 to cure the UV-curable resin f'. As the UV-curable resin f' cures, it adheres tightly to the first substrate 121, transferring the Fresnel shape of the mold M to the first substrate 121, forming the Fresnel structure f on the surface of the first substrate 121.

[0076] In addition, other materials and other manufacturing methods may also be used to manufacture the Fresnel structure, which is not limited here.

[0077] FIG8 is a second schematic diagram of the structure of the projection screen provided in an embodiment of the present application.

[0078] In some embodiments, as shown in FIG8 , the Fresnel structure layer 12 is an integrated structure, the surface of the Fresnel structure layer 12 facing the surface layer 11 is the Fresnel structure f, and the surface of the Fresnel structure layer 12 opposite to the surface layer 11 is a flat surface.

[0079] The use of an integrated Fresnel structure layer can omit the process of combining the substrate and the Fresnel structure, further simplifying the production process.

[0080] FIG9 is a third structural schematic diagram of the projection screen provided in an embodiment of the present application.

[0081] In some embodiments, as shown in FIG9 , the Fresnel structure layer may be made of a colored thermoplastic material having a tensile strength of 100 MPa or less.

[0082] In a specific implementation, the one-piece-molded Fresnel structure layer 12 can be manufactured by thermoforming. The Fresnel structure layer can be made of thermoplastic materials such as TPU or PVC, which is not limited here.

[0083] FIG. 10 is a second schematic diagram of the manufacturing process of the Fresnel structure layer provided in an embodiment of the present application.

[0084] Specifically, as shown in FIG10 , when a one-piece Fresnel structure layer is produced by a thermoforming method, a metal film may be evaporated or sputtered on one side of the thermoplastic material layer 12′ as a reflective layer 13, and then a heated mold M having a Fresnel structure is used to thermoform the thermoplastic material layer 12′ through the metal film, thereby forming a Fresnel structure layer 12 having a Fresnel structure with a metal film on the surface.

[0085] FIG11 is a fourth structural schematic diagram of the projection screen provided in an embodiment of the present application.

[0086] As shown in FIG. 11 , the surface layer 11 includes a second substrate 111 and a diffusion layer 112 .

[0087] The second substrate 111 serves as a substrate for the diffusion layer 112 . The second substrate 111 is in contact with the adhesive layer 14 . The diffusion layer 112 is located on a surface of the second substrate 111 opposite to the adhesive layer 14 .

[0088] Current projection systems typically use laser light sources. Lasers have high collimation, resulting in a smaller divergence angle for the projected light. The highly collimated light reflected from the projection screen also results in a smaller field of view. By providing a diffusion layer 112, the angle of light emitted after passing through it can be diversified, resulting in a certain divergence angle for the light ultimately emitted from the projection screen, increasing the viewer's field of view for the projected image. Furthermore, the diffusion layer 112 provides a certain degree of resistance to ambient light reflection, which helps improve image contrast. It also helps eliminate laser speckle and optimize the projected image.

[0089] The diffusion layer 112 can be formed on the surface of the second substrate 111 by incorporating diffusion particles into a resin material. The diffusion particles can be, but are not limited to, silicon dioxide particles, aluminum oxide particles, titanium oxide particles, cerium oxide particles, zirconium oxide particles, tantalum oxide particles, zinc oxide particles, and magnesium fluoride particles. The diffusion layer 112 can be produced using various coating methods, which are not limited here.

[0090] The second substrate 111 can be made of, but is not limited to, PET, PEN, PC, PMMA, TAC, COP, TPU, PVC, PI, PA, PE, PP and other materials.

[0091] In some embodiments, as shown in FIG11 , the second substrate 111 may contain a light-absorbing material. The light-absorbing material may generally be a light-absorbing pigment material. The second substrate 111 contains the pigment material and is colored so that the second substrate 111 has a light-absorbing property. This can thereby resist reflection of ambient light, improve the contrast of the projected image, and improve the black brightness of the projection screen.

[0092] FIG12 is a fifth structural diagram of the projection screen provided in an embodiment of the present application.

[0093] In some embodiments, as shown in FIG12 , the diffusion layer 112 may contain a light-absorbing material, and the diffusion layer 112 may be colored to form a colored diffusion layer. The colored diffusion layer has the properties of both diffusing and absorbing light, thereby simultaneously expanding the field of view angle, resisting ambient light reflection, and improving the black brightness of the projection screen.

[0094] FIG13 is a sixth structural diagram of the projection screen provided in an embodiment of the present application.

[0095] In some embodiments, as shown in FIG13 , the surface layer 11 includes only a second substrate 111. The second substrate 111 is in contact with the adhesive layer 14 and is bonded to the Fresnel structure layer 12 via the adhesive layer 14. The second substrate 111 is an atomized substrate. Atomized substrates have a certain light diffusion effect, which can expand the viewing angle. Atomized substrates can also reduce light reflection, thereby preventing light from forming a clear image on the ceiling. This has an anti-glare effect on the ceiling and can enhance the audience's viewing experience.

[0096] FIG14 is a seventh structural diagram of the projection screen provided in an embodiment of the present application.

[0097] In some embodiments, as shown in FIG14 , the second substrate can also contain a light-absorbing material to tint the atomized substrate. The tinted atomized substrate has both light-diffusing and light-absorbing properties, thereby expanding the viewing angle, reducing ceiling glare, and improving the black brightness of the projection screen by reducing ambient light reflection.

[0098] FIG15 is an eighth structural schematic diagram of the projection screen provided in an embodiment of the present application.

[0099] In some embodiments, as shown in FIG15 , the surface layer 11 includes only a second substrate 111, which is in contact with the adhesive layer 14 and is bonded to the Fresnel structure layer 12 via the adhesive layer 14. The surface of the second substrate 111 opposite the adhesive layer 14 is an uneven surface. The uneven surface can be formed by sandblasting or alkali treating the surface of the second substrate 111, which is not limited here. The uneven surface of the second substrate 111 can play a certain role in light diffusion and atomization, thereby expanding the viewing angle and preventing ceiling reflections.

[0100] FIG16 is a ninth structural diagram of the projection screen provided in an embodiment of the present application.

[0101] In some embodiments, as shown in FIG16 , the second substrate 111 may further contain a light-absorbing material, thereby coloring the second substrate 111. The colored second substrate simultaneously diffuses light, reduces light reflection, and absorbs light, thereby simultaneously expanding the viewing angle, resisting ambient light reflection, and improving the black brightness of the projection screen.

[0102] FIG17 is a tenth structural diagram of the projection screen provided in an embodiment of the present application.

[0103] In some embodiments, as shown in FIG17 , the surface layer 11 includes only a second substrate 111. The second substrate 111 is in contact with the adhesive layer 14 and is bonded to the Fresnel structure layer 12 via the adhesive layer 14. The second substrate 111 contains a light-absorbing material. By coloring the second substrate 111, the second substrate has light-absorbing properties, which can reduce ambient light reflection, increase the contrast of the projected image, and improve the black brightness of the projection screen.

[0104] When the surface layer 11 only includes the second substrate 111, by using a second substrate 111 made of special materials, surface treating the second substrate 111, or coloring the second substrate 111, the second substrate can be made to have the functions of light diffusion, anti-ambient light reflection, anti-ceiling reflection, etc., and the production of other film layers can be omitted, which is conducive to simplifying the production process.

[0105] FIG18 is an eleventh structural diagram of the projection screen provided in an embodiment of the present application.

[0106] In some embodiments, as shown in FIG18 , the adhesive layer 14 may contain a light-absorbing material and be colored so that the adhesive layer 14 has a light-absorbing property, thereby resisting ambient light reflection and improving the black brightness of the projection screen.

[0107] In specific implementation, carbon black, dyes and other light-absorbing materials can be used for coloring, which is not limited here. Specifically, the material of the film layer to be colored in the surface layer or the adhesive layer can contain materials such as carbon black and dyes to deepen the color of the film layer, thereby having a light-absorbing effect. It is worth noting that the coloring of the film layer in the projection screen can be achieved by making the material of the film layer contain pigment materials. The colored film layer has light-absorbing properties and can absorb the ambient light incident on the projection screen, thereby playing a role in resisting ambient light reflection, improving image contrast, and improving the black brightness of the projection screen. In addition, the colored film layer can absorb not only ambient light but also projection light. Therefore, it is necessary to adjust the light-shielding degree and transparency of the colored film layer by controlling the amount and color of the pigment material added, so as to better meet the requirements of projection screen use.

[0108] In specific implementation, each film layer in the surface layer of the projection screen and any film layer in the adhesive layer can be colored to meet the light absorption requirement.

[0109] Based on the same inventive concept, an embodiment of the present application further provides a projection system, as shown in FIG1 , the projection system includes: a projection device 2 and a projection screen 1 located on the light-emitting side of the projection device 2 .

[0110] FIG19 is a schematic structural diagram of a projection device provided in an embodiment of the present application.

[0111] As shown in Figure 19, the projection device includes: a light source device 21, an illumination optical path 22, a light modulation component 23, and a projection lens 24. The illumination optical path 22 is located on the light-exiting side of the light source device 21, the light modulation component 23 is located on the light-exiting side of the illumination optical path 22, and the projection lens 24 is located on the light-exiting side of the light modulation component 23.

[0112] The light source device 21 can be a laser light source device. The laser light source device can be a monochromatic laser, a laser that can emit laser light of multiple colors, or multiple lasers that emit laser light of different colors. When the laser light source device uses a monochromatic laser, the laser display device also needs to be provided with a color wheel, which is used for color conversion. The monochromatic laser combined with the color wheel can achieve the purpose of emitting primary color lights of different colors in a time sequence. When the laser light source device uses a laser that can emit laser light of multiple colors, it is necessary to control the laser light source to emit laser light of different colors as primary color lights in a time sequence.

[0113] In the embodiments of the present application, the light source device may employ a three-color laser light source device. This three-color laser light source device may be a laser that emits three primary colors of laser light, such as an MCL laser. Alternatively, it may include a red laser, a green laser, and a blue laser that emit three primary colors of laser light, respectively. Using a three-color laser light source device improves the color gamut of the projected image, providing better color expression and accurately reproducing the input image.

[0114] The illumination optical path 22 is located on the light-emitting side of the light source device 21. The illumination optical path 22 collimates the light emitted by the light source device 21 and allows the light emitted by the light source device 21 to be incident on the light modulation component 23 at a suitable angle. The illumination optical path 22 can include multiple lenses or lens groups, which are not limited here.

[0115] The light modulator 23 is used to modulate the incident light. In a specific implementation, the light modulator 23 can be a digital micromirror device (DMD). After passing through the illumination optical path 22, the light beam conforms to the illumination size and incident angle required by the DMD. The DMD surface includes numerous tiny mirrors, each of which can be individually driven to deflect. By controlling the DMD's deflection angle, the reflected light is incident on the projection lens 24.

[0116] The projection lens 24 is used to form an image of the output light of the light modulation component 23 . After the image is formed by the projection lens 24 , the image is projected.

[0117] In the embodiment of the present application, the projection device 2 can be an ultra-short-throw projection device, that is, the projection lens 24 in the projection device is an ultra-short-throw projection lens. The use of an ultra-short-throw projection device can greatly shorten the distance between the projection device 2 and the projection screen 1, thereby shortening the projection distance and achieving large-scale image display.

[0118] Projection screen 1 is located on the light-emitting side of a projection lens in a projection device. Projection screen 1 comprises a surface layer, a Fresnel structure layer, a reflective layer, and an adhesive layer. The adhesive layer is used to bond the surface layer to the Fresnel structure layer, which has a reflective layer formed thereon. The Fresnel structure is positioned facing the surface layer. This allows the adhesive layer to directly bond the surface layer to the reflective layer, eliminating the need for a protective layer on the reflective layer. This simplifies the process and reduces costs. The surface of the reflective layer covering the Fresnel structure that faces the surface layer serves as a reflective surface. This eliminates the need for projection light to first pass through the Fresnel structure layer before being reflected. Instead, projection light is directly reflected by the reflective layer on the surface of the Fresnel structure. This reduces the number of film layers that projection light passes through during its reflection from the projection screen, reducing light loss caused by reflection at the interfaces between the film layers and absorption by the film layers. More light is reflected forward, increasing gain. Since the Fresnel structure layer is located on the side farthest from the audience and no light enters the Fresnel structure layer, the requirements for the transmittance and damage specifications of the Fresnel structure layer are reduced. It is no longer necessary to use expensive optical materials to make the Fresnel structure layer, and cheaper industrial materials can be used for production, thereby reducing production costs.

[0119] In another aspect of an embodiment of the present application, a method for manufacturing a projection screen is provided. FIG20 is one of the flow charts of the method for manufacturing a projection screen provided in an embodiment of the present application.

[0120] As shown in FIG20 , the method for manufacturing a projection screen includes:

[0121] S10, providing a substrate, and performing surface treatment on the substrate to obtain a surface layer;

[0122] S20, manufacturing a Fresnel structure layer, and forming a reflective layer on a Fresnel structure surface of the Fresnel structure layer;

[0123] S30, using an adhesive layer to bond the surface layer and the surface of the Fresnel structure layer on which the reflective layer is formed.

[0124] The overall process of the method for manufacturing the projection screen provided in the embodiment of the present application is to first separately form a surface layer and a Fresnel structure layer with a reflective layer, and then bond the two parts with an adhesive layer.

[0125] The Fresnel structure layer can be formed by UV molding.

[0126] In some embodiments, as shown in FIG7 , a UV-curable resin f' is first applied to a mold M having a Fresnel structure on its surface. Next, a first substrate 121 is pressed with a predetermined pressure, and UV light is irradiated from one side of the first substrate 121 to cure the UV-curable resin f'. As the UV-curable resin cures, it adheres tightly to the first substrate 121. This transfers the Fresnel shape of the mold M to the first substrate 121, forming the Fresnel structure f on the surface of the first substrate 121.

[0127] Then, a metal thin film is evaporated or sputtered on the surface of the Fresnel structure f to form a reflective layer.

[0128] In a specific implementation, the first substrate 121 can be made of, but not limited to, PET, PEN, PC, PMMA, TAC, COP, TPU, PVC, PI, PA, PE, PP, etc. The metal film can be made of, but not limited to, aluminum, silver, titanium, etc.

[0129] In some embodiments, referring to FIG10 , when an integrally formed Fresnel structure layer is produced by a thermoforming method, a metal film is evaporated or sputtered on one side of a thermoplastic material layer 12 ′ as a reflective layer 13, and then a heated mold M having a Fresnel structure is used to thermoform the thermoplastic material layer 12 ′ through the metal film, thereby forming a Fresnel structure layer 12 having a Fresnel structure with a metal film on the surface.

[0130] In a specific implementation, the first substrate 121 can be made of thermoplastic materials such as TPU or PVC, and the metal film can be made of metals such as aluminum, silver, and titanium, which are not limited here.

[0131] In the embodiment of the present application, the surface layer can be made by performing surface treatment on the substrate in different ways. In order to distinguish the substrate in the Fresnel structure layer from the substrate in the surface layer, the substrate in the surface layer is referred to as the second substrate.

[0132] In some embodiments, to expand the viewing angle of the projection screen, a diffusion layer may be formed on the surface of the second substrate to diffuse light. Alternatively, the second substrate may contain diffusion particles to impart a light-diffusing effect to the second substrate.

[0133] The diffusion layer can be formed by incorporating diffusion particles into a resin material and then coating the diffusion layer material onto the surface of the second substrate using various coating methods. Incorporating diffusion particles into the second substrate material allows the second substrate to directly exhibit light diffusion properties during the formation of the second substrate. The diffusion particles can be, but are not limited to, silica particles, aluminum oxide particles, titanium oxide particles, cerium oxide particles, zirconium oxide particles, tantalum oxide particles, zinc oxide particles, magnesium fluoride particles, and the like, without limitation.

[0134] In some embodiments, in order to prevent the projection light from reflecting on the outermost surface of the projection screen and forming ceiling light, the second substrate can be an atomized substrate, or the surface of the formed surface layer on the viewer side can be atomized.

[0135] The atomized substrate can be made of a material with haze to form the second substrate, and the atomized surface can be obtained by sandblasting or alkali treating the second substrate or the film layer on the surface of the second substrate, which is not limited here.

[0136] In some embodiments, in order to improve the contrast of the projection screen, any one of the surface layers or the adhesive layer can be colored so that the colored film layer has a light-absorbing effect, thereby absorbing the ambient light incident on the projection screen and improving the image contrast.

[0137] In order to color any of the surface layers or adhesive layers, the film layer material may be made to contain a light-absorbing material, such as carbon black or a dye, to darken the color of the film layer and make it absorb light, without limitation. The coloring method can be freely selected as appropriate and is not limited thereto.

[0138] During specific implementation, different forms of surface layers can be produced according to actual use so that they have corresponding functions. The embodiments of the present application do not limit the specific form of the surface layer.

[0139] After the surface layer and the Fresnel structure layer with the reflective layer are prepared, the two are bonded together using an adhesive layer to produce a projection screen.

[0140] In an embodiment of the invention, the substrate in the surface layer (and the film layer on the substrate) and the Fresnel structure layer can also be made of flexible materials, so that the projection screen can be manufactured in conjunction with a roll-to-roll process to improve the production throughput.

[0141] FIG21 is a second flowchart of the method for manufacturing a projection screen provided in an embodiment of the present application.

[0142] Specifically, as shown in FIG21 , when a projection screen is manufactured using a roll-to-roll process, the manufacturing method includes:

[0143] S100, making a roll of the surface layer;

[0144] S200, making a roll of adhesive layer;

[0145] S300, using a roll-to-roll process, laminating the adhesive layer to the substrate of the surface layer;

[0146] S400 , using a roll-to-roll process, laminating the Fresnel structure layer with the reflective layer to the adhesive layer, thereby using the adhesive layer to bond the surface layer and the surface of the Fresnel structure layer with the reflective layer to each other.

[0147] This embodiment of the present application uses a structure in which the surface layer forms a diffusion layer on the surface of a substrate as an example to specifically illustrate the roll-to-roll process for producing projection screens. When the surface layer adopts other structures, it may not involve forming other film layers on the surface of the substrate, and the same diffusion effect can be achieved through other methods. Furthermore, to distinguish between the substrate in the Fresnel structure layer and the substrate in the surface layer, the substrate in the Fresnel structure layer is referred to as the first substrate, and the substrate in the surface layer is referred to as the second substrate.

[0148] 22 to 25 are schematic diagrams of the production process of the projection screen provided in the embodiment of the present application.

[0149] Specifically, as shown in FIG. 22 , a diffusion layer 112 may be stacked on the surface of a second base material 111 to form a surface layer 11 .

[0150] Because the manufacturing method shown in the embodiment of this application is a roll-to-roll process, the second substrate 111 needs to be made of a flexible material with curling properties, such as flexible PET, with a thickness appropriately selected between 38μm and 250μm. The diffusion layer 112 can be manufactured using various coating methods, which are not limited here. The diffusion layer 112 can have anisotropic diffusion function.

[0151] The surface layer 11 is produced and formed into a roll of the surface layer, which is referred to as the first roll J1.

[0152] At the same time, as shown in Figure 22, an adhesive layer 14 is provided and rolled up to form a second roll J2. As shown in Figure 22, separators s1 and s2 are generally provided on both sides of the adhesive layer 14 to prevent the adhesive layers 14 from sticking to each other during the rolling process.

[0153] The adhesive layer 14 needs to have stable adhesive strength. In a specific implementation, the adhesive layer 14 may be made of PSA. The PSA preferably has a storage modulus of 100 kPa or less at room temperature and a thickness of 50 μm or more.

[0154] As shown in Figure 23, while peeling off the separation layer s1 on the light peeling side of the adhesive layer 14 in the second roll J2, it is adhered to the second substrate surface of the first roll J1 to form the third roll J3 with the structure of surface layer 11 / adhesive layer 14 / separation layer s2 as shown in Figure 24.

[0155] In the embodiments of the present application, the Fresnel structure layer 12 can be produced using any of the aforementioned methods, without limitation. Taking the structure shown in FIG. 25 as an example, the Fresnel structure layer 12 can be produced by UV molding a Fresnel structure on the surface of an industrial PET substrate (i.e., the first substrate). The thickness of the industrial PET substrate can be freely selected between 25 μm and 350 μm, without limitation.

[0156] After the Fresnel structure layer 12 is produced, a roll of the Fresnel structure layer 12 is produced, and a metal film is evaporated or sputtered on the surface of the Fresnel structure using a roll-to-roll sputtering process to form a reflective layer 13, thereby obtaining a fourth roll J4 of the Fresnel structure layer with a metal film.

[0157] Furthermore, as shown in FIG25 , the separation layer s2 on the heavy peeling side of the other side of the adhesive layer 14 in the third volume J3 is peeled off while being bonded to the Fresnel structure layer of the fourth volume J4 to produce the fifth volume J5 of the surface layer 11 / adhesive layer 14 / Fresnel structure as shown in FIG25 .

[0158] Next, unroll the fifth roll, J5, and cut it to the required dimensions for the projection screen, completing the production of the projection screen. If bubbles remain in the Fresnel structure layer due to the adhesive layer not being filled, an Auto Clave treatment can be performed. For example, the treatment conditions can be 50°C, 0.9 MPa, and 30 minutes.

[0159] In one embodiment, a projection screen includes a surface layer, a Fresnel structure layer, a reflective layer, and an adhesive layer. The adhesive layer is used to bond the surface layer to the Fresnel structure layer having the reflective layer formed thereon. The Fresnel structure is positioned facing the surface layer, allowing the adhesive layer to directly bond the surface layer to the reflective layer. This eliminates the need for a protective layer on the metal film reflective layer, simplifying the process and reducing costs. Furthermore, by forming the metal film reflective layer on the Fresnel structure through evaporation or sputtering, with the surface of the surface layer facing the reflective layer serving as the reflective surface, projection light does not need to first pass through the Fresnel structure layer before being reflected. Instead, it is directly incident on the reflective layer on the surface of the Fresnel structure and is reflected. Consequently, the number of film layers that projection light passes through during its reflection from the projection screen is reduced, reducing light loss caused by reflection at the interfaces between the film layers and absorption by the film layers. More light is reflected forward, thereby increasing gain. Since the Fresnel structure layer is located on the side farthest from the audience and no light enters the Fresnel structure layer, the requirements for the transmittance and damage specifications of the Fresnel structure layer are reduced. It is no longer necessary to use expensive optical materials to make the Fresnel structure layer, and cheaper industrial materials can be used for production, thereby reducing production costs.

[0160] In one embodiment, the Fresnel structure layer includes a first substrate, wherein the surface of the first substrate facing the surface layer and the surface opposite to the surface layer are both flat surfaces, and the Fresnel structure is located on the surface of the first substrate facing the surface layer. The Fresnel structure can be fabricated on the surface of the first substrate using a mold M having the Fresnel structure and a UV curable resin through a UV molding process.

[0161] In one embodiment, the Fresnel structure layer is an integrated structure. The surface of the Fresnel structure layer facing the surface layer is the Fresnel structure, and the surface of the Fresnel structure layer opposite the surface layer is a flat surface. Using an integrated Fresnel structure layer eliminates the need to bond the substrate to the Fresnel structure, further simplifying the manufacturing process.

[0162] In one embodiment, the Fresnel structure layer may be made of a colored or transparent thermoplastic material with a tensile strength of less than 100 MPa and manufactured by thermoforming.

[0163] In one embodiment, the surface layer includes a second substrate and a diffusion layer. The second substrate serves as the base material for the diffusion layer, which contacts the adhesive layer. The diffusion layer is located on the surface of the second substrate opposite the adhesive layer. The diffusion layer can diversify the angle of light emitted after passing through the diffusion layer, thereby ensuring that the light ultimately emitted by the projection screen has a certain diffusion angle, thereby increasing the viewing angle of the projected image for the viewer. Furthermore, the diffusion layer can also prevent glare from the ceiling.

[0164] In one embodiment, the second substrate may contain a light absorbing material, which may be a pigment material with light absorbing properties. By absorbing ambient light in the second substrate, black luminance is improved, thereby increasing the contrast of the projected image.

[0165] In one embodiment, the diffusion layer can contain a light-absorbing material and be colored to form a colored diffusion layer. The colored diffusion layer has the properties of both diffusing and absorbing light, thereby improving the black brightness of the projection screen by expanding the field of view angle and absorbing ambient light.

[0166] In one embodiment, the surface layer only includes the second substrate, and the second substrate adopts an atomized substrate. The atomized substrate has a certain light diffusion effect, which can expand the field of view angle. The atomized substrate can also reduce the reflection of light, thereby avoiding the light from forming a clear image on the ceiling. It has an anti-ceiling reflection effect and can enhance the audience's viewing experience.

[0167] In one embodiment, the second substrate can contain a light-absorbing material to color the atomized substrate. The colored atomized substrate simultaneously reduces light reflection, diffuses light, and absorbs light, thereby simultaneously preventing ambient light reflection and ceiling glare, thereby improving the black brightness of the projection screen.

[0168] In one embodiment, the surface layer comprises only a second substrate, and the surface of the second substrate opposite the adhesive layer is uneven. The uneven surface can be formed by grinding the surface of the second substrate or subjecting the surface of the second substrate to sandblasting or alkali treatment. The uneven surface of the second substrate has a certain light diffusion effect, thereby expanding the viewing angle and preventing ceiling glare.

[0169] In one embodiment, a colored substrate containing a light-absorbing material in the second substrate is used, and the surface of the second substrate is sandblasted or alkali-treated so that it has both light diffusion and light absorption properties, thereby improving the black brightness of the projection screen by expanding the viewing angle and absorbing ambient light.

[0170] In one embodiment, the surface layer includes only the second substrate, and the second substrate 111 contains a light-absorbing material. The second substrate is colored to have a light-absorbing property, which can improve the black brightness of the projection screen and enhance the contrast of the projected image by absorbing ambient light.

[0171] In one embodiment, the adhesive layer may contain a light-absorbing material and be colored to make the adhesive layer have light-absorbing properties, thereby preventing ambient light reflection and improving the black brightness of the projection screen.

[0172] In one embodiment, a method for manufacturing a projection screen includes: providing a substrate and performing surface treatment on the substrate to obtain a surface layer; forming a Fresnel structure layer, forming a reflective layer on the Fresnel structure surface of the Fresnel structure layer; and bonding the surface layer to a side of the Fresnel structure layer on which the reflective layer is formed, using an adhesive layer. The overall process of the projection screen manufacturing method involves first separately forming the surface layer and the Fresnel structure layer with the reflective layer, and then bonding the two parts using an adhesive layer.

[0173] In one embodiment, a method for manufacturing a projection screen includes: producing a roll of a surface layer; producing a roll of an adhesive layer; laminating the adhesive layer to a substrate of the surface layer using a roll-to-roll process; and laminating a Fresnel structure layer with a reflective layer to the adhesive layer using a roll-to-roll process, thereby bonding the surface layer to the side of the Fresnel structure layer with the reflective layer via the adhesive layer. The overall process of the projection screen manufacturing method involves first separately forming the surface layer and the Fresnel structure layer with the reflective layer, and then bonding the two components using the adhesive layer. Using a roll-to-roll process can improve process throughput.

[0174] Although the preferred embodiments of the present application have been described, those skilled in the art may make additional changes and modifications to these embodiments once they have learned the basic creative concept. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications that fall within the scope of the present application.

Claims

1. A projection screen, characterized in that: include: surface layer; A Fresnel structure layer is located on one side of the surface layer, and a Fresnel structure is provided on a surface of the Fresnel structure layer facing the surface layer; a reflective layer, located on a surface of the Fresnel structure layer facing the surface layer; and An adhesive layer is located between the surface layer and the reflective layer, and is used to bond the surface layer to a surface of the Fresnel structure layer on which the reflective layer is provided.

2. The projection screen according to claim 1, wherein The reflective layer is a metal film.

3. The projection screen according to claim 1, wherein The Fresnel structure layer includes a first substrate, a surface of the first substrate facing the surface layer and a surface opposite to the surface layer are both flat surfaces, and the Fresnel structure is located on the surface of the first substrate facing the surface layer.

4. The projection screen according to claim 1, wherein The Fresnel structure layer is an integrated structure, a surface of the Fresnel structure layer facing the surface layer is a Fresnel structure, and a surface of the Fresnel structure layer opposite to the surface layer is a flat surface.

5. The projection screen according to claim 4, wherein: The Fresnel structure layer is made of thermoplastic material.

6. The projection screen according to any one of claims 1 to 5, wherein: The surface layer comprises: a second substrate in contact with the adhesive layer; and The diffusion layer is located on the surface of the second substrate opposite to the adhesive layer.

7. The projection screen according to claim 6, wherein: The second substrate contains a light-absorbing material; or the diffusion layer contains a light-absorbing material.

8. The projection screen according to any one of claims 1 to 5, wherein: The adhesive layer contains a light absorbing material.

9. A projection system, characterized in that: include: A projection device, for emitting projection light; and A projection screen is located on the light-emitting side of the projection device, and the projection screen is the projection screen according to any one of claims 1 to 8.

10. The projection system according to claim 9, wherein: The projection device is an ultra-short-throw laser projection device; the projection device includes: A three-color laser light source device for emitting three-primary-color lasers; a light modulation component, located on the light-emitting side of the three-color laser light source device, for modulating the laser light emitted by the three-color laser light source device; The projection lens is located on the light-emitting side of the light modulation component.

11. A method for manufacturing a projection screen, characterized in that: include: a surface treatment step of providing a substrate and performing surface treatment on the substrate to obtain a surface layer; A Fresnel structure manufacturing step, manufacturing a Fresnel structure layer, and forming a reflective layer on the Fresnel structure surface of the Fresnel structure layer; and In the bonding step, the surface layer and the surface of the Fresnel structure layer on which the reflective layer is formed are bonded to each other using an adhesive layer.

12. The production method according to claim 11, wherein: The Fresnel structure manufacturing process includes: Providing a first substrate, and forming a Fresnel structure on a surface of the first substrate using an ultraviolet curable resin; and The reflective layer is formed on the surface of the Fresnel structure.

13. The production method according to claim 11, wherein: The Fresnel structure layer is made of thermoplastic material; The Fresnel structure manufacturing process includes: Providing a first substrate, wherein the first substrate is made of thermoplastic material; forming a reflective layer on the surface of the first substrate; and The first substrate is thermoformed on one side of the reflective layer to form a Fresnel structure on the surface of the first substrate, and the reflective layer is located on the surface of the Fresnel structure.

14. The production method according to claim 12 or 13, characterized in that: Forming a reflective layer on the Fresnel structure surface of the Fresnel structure layer comprises: A metal film is evaporated or sputtered on the surface of the Fresnel structure layer to form the reflective layer.

15. The production method according to any one of claims 11 to 13, characterized in that: The substrate of the surface layer and the Fresnel structure layer are both made of flexible materials; The bonding process includes: making a roll of the surface layer; making a roll of the adhesive layer; Adhesive layer is laminated to the substrate of surface layer by roll-to-roll process; The Fresnel structure layer with the reflective layer is bonded to the side of the adhesive layer opposite to the surface layer using a roll-to-roll process, and the surface layer and the surface of the Fresnel structure layer with the reflective layer are bonded to each other using the adhesive layer.

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