Orthographic projection screen and manufacturing method thereof

Abstract

The invention discloses an orthographic projection screen, and belongs to the field of projection display, the orthographic projection screen comprises a surface layer and a reflecting layer, the surface layer is a microstructure layer, and one side, far away from the reflecting layer, of the microstructure layer is a non-smooth surface; the microstructure layer is formed by surface glue, and the thickness of the microstructure layer is 10 microns to 500 microns; the reflecting layer is formed by mixing bonding glue and reflecting particles, and the weight ratio of the reflecting particles in the reflecting layer is one ten thousandth to twenty percent; the invention further discloses a corresponding manufacturing method. The orthographic projection screen has the advantages of being resistant to aging, high in ultraviolet resistance and good in stability, and the reliability and the use economical efficiency of the orthographic projection screen are effectively improved.

Description

[0001] This application relates to the field of projection display, specifically to a front projection screen and its manufacturing method. Background Technology

[0002] In daily use, the most significant drawback of existing front projection screens is that their materials are prone to aging, severely limiting their lifespan and display quality. Typically, after 3 to 5 years, the edges of the screen will turn noticeably yellow due to material oxidation and additive volatilization, leading to color distortion and decreased image uniformity. After 5 to 8 years of continuous use, under the long-term effects of ultraviolet light and heat, the surface coating will chalk, causing image blurring and reduced sharpness. This physical damage is irreversible, and the screen must be replaced.

[0003] These problems not only significantly reduce the visual quality of images but also substantially increase long-term maintenance costs and the frequency of device upgrades for users. In response to this situation, the industry urgently needs to develop screens that are more resistant to aging and UV radiation to improve reliability and cost-effectiveness. Summary of the Invention

[0004] This application discloses a front projection screen, which has strong aging resistance, UV resistance, and good stability, effectively improving the reliability and cost-effectiveness of the front projection screen.

[0005] The technical solution provided in this application is as follows:

[0006] A front projection screen includes a surface layer and a reflective layer. The surface layer is a microstructure layer, and the side of the microstructure layer away from the reflective layer is a non-smooth surface. The microstructure layer is formed by a surface adhesive and has a thickness of 10 to 500 micrometers. The reflective layer is formed by a mixture of adhesive and reflective particles, and the reflective particles account for 1 / 10,000 to 20% of the weight of the reflective layer.

[0007] In this application, by setting the side of the microstructure layer away from the reflective layer to be a non-smooth surface, the diffusion angle of the microstructure layer is effectively controlled. The microstructure layer is composed of a surface adhesive, exhibiting slight physical adhesion, suitable for temporary positioning, and easy to peel off from roller molds, etc. After prolonged exposure to high temperatures, its morphological structure remains relatively stable, exhibiting strong aging resistance, UV resistance, and good stability, which is beneficial to improving the reliability and economic efficiency of the entire front projection screen. The thickness of the microstructure layer is limited to 10–500 micrometers to avoid excessive thickness, which would affect the diffusion ability of the microstructure layer; and to avoid excessive thinness, which could lead to localized damage to the microstructure layer during lamination with other structures and demolding.

[0008] In this application, the reflective layer is formed by mixing adhesive and reflective particles. The high reflectivity and diffuse reflectivity of the reflective particles reflect incident light back. The weight percentage of the reflective particles in the reflective layer is limited to 1 / 10,000 to 20%, ensuring the reflective properties of the reflective layer and thus ensuring the imaging display effect of the entire projection screen.

[0009] Furthermore, the adhesive comprises an organosilicon polymer, wherein the organosilicon polymer accounts for no less than 70% by weight in the adhesive.

[0010] Furthermore, the adhesive also includes an adhesive filler, wherein the adhesive filler accounts for no more than 30% of the total weight of the adhesive.

[0011] In this application, the adhesive comprises a silicone polymer and an adhesive filler, ensuring that the resulting microstructure layer has low adhesion and is easy to peel off. The microstructure layer formed by the above materials is relatively stable, with strong aging resistance and UV resistance, which is beneficial to improving the reliability and economic efficiency of the entire front projection screen. Limiting the weight ratio of the silicone polymer and the adhesive filler allows for effective control of the stability of the microstructure layer. Furthermore, controlling the silicone polymer material in the adhesive makes the front projection screen easy to roll up and provides flame retardancy, improving the safety performance of the front projection screen.

[0012] Furthermore, the reflective layer is formed by uniformly mixing the adhesive and the reflective particles.

[0013] In this application, a reflective layer is formed by uniformly mixing adhesive and reflective particles, resulting in better uniformity of reflected light.

[0014] Furthermore, the particle sizes of the reflected particles are not entirely the same.

[0015] In this application, the particle size of the reflective particles does not have to be exactly the same. This way, it is not necessary to strictly control the reflective particles to a certain specification, which is beneficial to cost control.

[0016] Furthermore, the particle size of the reflective particles is 0.05 micrometers to 10 micrometers.

[0017] In this application, setting the particle size of the reflective particles within a certain range is beneficial to the uniformity of the mixture of reflective particles and adhesive.

[0018] Furthermore, the front projection screen also includes an adhesive layer and a base fabric layer, which are sequentially disposed on the side of the reflective layer away from the microstructure layer. The adhesive layer includes a silicone material and has a thickness of 50 micrometers to 100 micrometers; the base fabric layer has a thickness of 30 micrometers to 1000 micrometers.

[0019] In this application, in addition to the surface layer and reflective layer, the front projection screen may also include an adhesive layer and a base fabric layer. This base fabric layer restricts the elasticity of the reflective and surface layers within a certain range, preventing severe localized deformation of the front projection screen during rolling and unfolding, thus further enhancing its stability. Furthermore, the addition of the base fabric layer and adhesive layer also improves the overall wrinkle resistance, stiffness, and surface smoothness of the front projection screen.

[0020] In this application, the material and thickness of the adhesive layer are set to effectively control the adhesive force of the adhesive layer, ensure the bonding stability between the reflective layer and the base fabric layer, and thus enhance the stability of the front projection screen.

[0021] In this application, the thickness of the adhesive layer and the base fabric layer is controlled, which to some extent controls the thickness of the front projection screen, reduces the requirements for the installation wall, and makes it more universal; it avoids the problem that the front projection screen is too thick, the whole is heavy, and the installation and transportation costs are high.

[0022] Furthermore, the thickness of the base fabric layer is 30 micrometers to 800 micrometers.

[0023] This application also provides a method for creating a front projection screen, including the following steps:

[0024] S100. Fabrication of surface layer: Design an optical microstructure through optical simulation, manufacture a roller mold with the optical microstructure, fabricate an intermediate surface film containing the optical microstructure based on the roller mold, apply a surface adhesive to the intermediate surface film, smooth it, and cure it to form a surface layer with a thickness of 10 micrometers to 500 micrometers.

[0025] S200. Making a reflective layer: After mixing the adhesive and reflective particles, apply the mixture to the surface layer and cure it to form a reflective layer. The reflective particles account for one ten-thousandth to twenty percent of the weight of the reflective layer.

[0026] The surface layer and reflective layer, which are formed by the aforementioned steps, are peeled off from the intermediate surface film to form a front projection screen.

[0027] In this application, by limiting the manufacturing process and thickness of the surface layer, as well as the material ratio of the reflective layer, the surface layer and reflective layer peeled from the intermediate surface film are made more stable, resistant to aging and UV radiation, while ensuring the imaging display effect of the front projection screen.

[0028] Furthermore, the curing temperature in step S100 is 60℃~160℃, and the curing temperature in step S200 is 60℃~160℃.

[0029] In this application, the curing temperature of each step is controlled, thereby controlling the curing time of each step, which facilitates the control of the temperature and time of the entire manufacturing process and ensures the orderly and stable progress of the process.

[0030] Furthermore, before demolding, the production method for projecting onto a screen also includes:

[0031] S300, Adhesive layer coating: Apply a silicone material with adhesive properties to the reflective layer, smooth it to form an adhesive layer, and prepare the base fabric;

[0032] S400, Composite Curing: The base fabric is composited onto the adhesive layer and cured to form a base fabric layer.

[0033] In this application, an adhesive layer and a base fabric layer are provided on top of the surface layer and the reflective layer to control the elasticity of the reflective layer and the surface layer within a certain range, thereby enhancing the stability of the front projection screen. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the front projection screen structure of Embodiment 1 of this application;

[0035] Figure 2 yes Figure 1 A simplified diagram of the front projection screen manufacturing process;

[0036] Figure 3 This is a schematic diagram of the front projection screen structure of Embodiment 2 of this application;

[0037] Figure 4 yes Figure 3 A simplified diagram of the front projection screen manufacturing process;

[0038] Figure 5 yes Figure 4 Simplified diagram of step S100;

[0039] Figure 6 yes Figure 4 Simplified diagram of step S200;

[0040] Figure 7 yes Figure 4 Simplified diagram of step S300;

[0041] Figure 8 yes Figure 4 Simplified diagram of steps S400.

[0042] The meanings of the reference numerals in the figure are as follows:

[0043] 1000 - Microstructure layer; 2000 - Reflective layer; 3000 - Adhesive layer; 4000 - Base fabric layer; 5000 - Intermediate surface film. Detailed Implementation

[0044] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0045] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0046] Example 1

[0047] Figure 1 This is a schematic diagram of the front projection screen structure according to Embodiment 1 of this application. Figure 1 As shown, the front projection screen includes a surface layer and a reflective layer 2000. The surface layer is a microstructure layer 1000, and on the side away from the reflective layer 2000, the microstructure layer 1000 has a non-smooth surface. Here, the microstructure layer 1000 is formed by a surface adhesive, and the thickness of the microstructure layer 1000 is 10 micrometers to 500 micrometers. The reflective layer 2000 is formed by a mixture of adhesive and reflective particles, and the weight percentage of the reflective particles in the reflective layer 2000 is 1 / 10,000 to 20%.

[0048] In the embodiments of this application, by setting the side of the microstructure layer 1000 away from the reflective layer 2000 to be a non-smooth or textured surface, the diffusion angle of the microstructure layer 1000 can be effectively controlled. Specifically, the diffusion angle of the microstructure layer 1000 can be set according to specific requirements such as the gain of the projection screen, thereby controlling the setting of the non-smooth surface of the microstructure layer 1000.

[0049] In the embodiments of this application, the microstructure layer 1000 is formed from a surface adhesive. The surface adhesive itself has low viscosity and weak adhesion, making the microstructure layer 1000 formed by the surface adhesive easy to peel off. In addition, even after long periods and high temperatures, the surface adhesive's morphological structure remains relatively stable, exhibiting strong aging resistance and UV resistance. Consequently, the resulting microstructure layer possesses characteristics of aging resistance and good stability, which is beneficial for improving the reliability and cost-effectiveness of front projection screens.

[0050] As a further explanation, the adhesive can be a silicone polymer. The silicone polymer is the base of the adhesive, and its main component can be polydimethylsiloxane, such as hydroxyl-terminated polydimethylsiloxane. Due to the specific properties of silicone polymers (such as elasticity, chemical inertness, and resistance to high and low temperatures), the adhesive has excellent flexibility, resilience, and stability over a wide temperature range (-40℃ to 200℃).

[0051] As a further explanation, the adhesive may include a silicone polymer and an adhesive filler, with the silicone polymer as the base and the adhesive filler as an auxiliary material. Additives, such as silicone oil, may also be added appropriately. Here, the adhesive filler can be used to control the diffusion angle of the microstructure layer 1000. The adhesive filler can be made of alumina, aluminum nitride, boron nitride, beryllium oxide, zinc oxide, silicon carbide, etc. From a cost perspective, alumina or a mixture of alumina and others is preferred to balance cost and performance. There are no strict requirements for the particle size of the adhesive filler; different particle sizes (e.g., large, medium, and small) are blended according to the required diffusion angle of the microstructure layer 1000.

[0052] As a further supplementary explanation, the silicone polymer in the adhesive layer shall account for no less than 70% by weight. On this basis, adhesive filler may be included, but its weight percentage shall not exceed 30%. By limiting the weight percentage range of the silicone polymer and adhesive filler, the diffusion angle and stability of the formed microstructure layer are effectively controlled. Controlling the weight percentage of the silicone polymer in the adhesive layer gives the microstructure layer 1000 a certain degree of flexibility and elastic tension, making it easy to roll up, thus enabling the front projection screen to be rolled up. It also gives the microstructure layer 1000 a certain degree of flame retardancy, enhancing the flame retardant and fireproof performance of the front projection screen and improving its safety performance.

[0053] In the embodiments of this application, the thickness of the microstructure layer 1000 is limited to 10 micrometers to 500 micrometers. This avoids excessive thickness, which would affect the diffusion effect of the microstructure layer, and excessive thinness, which would lead to localized damage to the microstructure layer during composite with other structures or demolding. At the same time, this improves economic efficiency while ensuring the diffusion capability of the microstructure layer.

[0054] As a further explanation, the thickness of the microstructure layer 1000 can be 10 micrometers, 20 micrometers, 30 micrometers, 40 micrometers, 50 micrometers, 80 micrometers, 100 micrometers, 150 micrometers, 200 micrometers, 250 micrometers, 300 micrometers, 350 micrometers, 400 micrometers, 450 micrometers, 500 micrometers, etc., and the specific thickness setting is adapted to the reflective layer 2000.

[0055] In the embodiments of this application, the composition of the reflective layer 2000 is defined. The reflective layer 2000 is formed by mixing adhesive and reflective particles. The high reflectivity and diffuse reflectivity of the reflective particles reflect incident light back. The weight ratio of reflective particles in the reflective layer 2000 is defined as one ten-thousandth to twenty percent to ensure the reflective characteristics of the reflective layer 2000, thereby ensuring the imaging display effect of the projection screen.

[0056] As a further explanation, the adhesive in the reflective layer 2000 uses an organosilicon polymer as its base material. The main component of this organosilicon polymer can be a polyorganosiloxane, such as hydroxyl-terminated polydimethylsiloxane or vinyl polydimethylsiloxane. Based on the inherent properties of organosilicon polymers (such as elasticity, chemical inertness, and resistance to high and low temperatures), the reflective layer also possesses excellent flexibility, resilience, and stability over a wide temperature range (-40℃ to 200℃). The reflective particles can be inorganic materials with high reflectivity and diffuse reflection characteristics, dispersed within the organosilicon polymer, thus forming the reflective layer 2000 with reflective and diffuse reflection properties.

[0057] To further explain, the reflective particles can be one or more combinations of titanium dioxide, barium sulfate, zinc oxide, and silicon dioxide. These materials have relatively high refractive indices and stable chemical properties, thus ensuring the reflective characteristics and stability of the reflective layer 2000, and guaranteeing the stability of the front projection screen imaging display.

[0058] As a further option, titanium dioxide can be used directly as the reflective particle, or titanium dioxide can be combined with other reflective particle materials to control material costs while ensuring the high reflectivity and stability of the reflective layer.

[0059] In the embodiments of this application, the reflective particles and adhesive are uniformly mixed to form a reflective layer. This results in a uniform distribution of reflective particles, which improves the uniformity of the light reflected by the reflective layer and ensures the uniformity of the image display on the projected screen.

[0060] In the embodiments of this application, the particle size of the reflective particles may not be completely uniform. Here, the particle size of the reflective particles refers to their diameter. By not imposing uniform requirements on the particle size, it is not necessary to strictly control the reflective particles to a certain specification, effectively reducing production and procurement costs and facilitating cost control.

[0061] In the embodiments of this application, the particle size of the reflective particles is 0.05 micrometers to 10 micrometers. Setting the particle size of the reflective particles within a certain range is beneficial to the uniformity of the mixture of the reflective particles and the adhesive. Here, the particle size of the reflective particles can be 0.05 micrometers, 0.1 micrometers, 0.5 micrometers, 1 micrometer, 3 micrometers, 5 micrometers, 8 micrometers, 10 micrometers, etc.

[0062] As a further explanation, using the aforementioned reflective particles to form the reflective layer 2000 can effectively cause uniform scattering or reflection of projected light, resulting in uniform image brightness. When the particle size of the reflective particles is less than 0.05 micrometers, the scattering or reflection of projected light is reduced, and the brightness of the projected screen decreases; when the particle size of the reflective particles is greater than 10 micrometers, the diffraction effect between the projected light and the reflective particles is enhanced, and the scattering or reflection of projected light is also reduced, resulting in a decrease in the brightness of the projected screen.

[0063] In the embodiments of this application, the thickness of the front projection screen can be set to between 100 micrometers and 1000 micrometers. When the thickness of the front projection screen is less than 100 micrometers, it is too flexible and difficult to flatten after being rolled up; when the thickness of the front projection screen is greater than 1000 micrometers, rolling it up becomes quite difficult. Setting the thickness of the front projection screen to between 100 micrometers and 1000 micrometers allows for the utilization of the elasticity of the reflective layer and the microstructure layer to achieve the rollability of the front projection screen; it also makes it relatively easy to flatten after being rolled up.

[0064] Figure 2 for Figure 1 A simplified diagram of the front projection screen manufacturing process. See also... Figure 2 The aforementioned method for manufacturing a projection screen includes the following steps:

[0065] S100. Fabrication of surface layer: Design optical microstructures through optical simulation, manufacture roller molds with optical microstructures, fabricate intermediate surface film 5000 containing optical microstructures based on roller molds, apply adhesive to intermediate surface film 5000, smooth it, and cure it to form a surface layer with a thickness of 10 micrometers to 500 micrometers.

[0066] S200. Making the reflective layer: After mixing the adhesive and reflective particles, apply the mixture to the surface layer and cure it to form a reflective layer.

[0067] The surface layer and reflective layer are formed by stacking the aforementioned steps and then separated from the intermediate surface film 5000 to form a front projection screen.

[0068] Among them, the weight ratio of reflective particles in the reflective layer is from one ten-thousandth to twenty percent.

[0069] To further explain, before fabricating the surface layer, it is necessary to design the optical microstructure through optical simulation and manufacture a roller mold containing the optical microstructure. Then, based on the roller mold, an intermediate surface film containing the optical microstructure is fabricated. A surface adhesive is then applied to the intermediate surface film, smoothed, and cured to form the surface layer. In this way, the designed optical microstructure can be presented on the surface layer, forming a non-smooth surface according to design requirements, thus effectively controlling the diffusion angle of the surface layer. Here, the use of a surface adhesive results in minimal physical adhesion to the formed surface layer, facilitating subsequent peeling from the intermediate surface film. Furthermore, the surface adhesive exhibits relatively stable morphology and structure after prolonged exposure to high temperatures, demonstrating strong overall aging resistance, UV resistance, and good stability.

[0070] As a further explanation, limiting the thickness of the surface layer ensures good stability of the surface layer while maintaining the imaging display effect, thereby improving the reliability and cost-effectiveness of the manufactured front projection screen.

[0071] In addition, the adhesive also has the characteristics of elasticity and flame retardancy. The surface layer made with the adhesive ensures that the surface layer has a certain degree of flexibility and elastic tension, making it easy to roll up and enhancing the rollability of the front projection screen. The surface layer made with the adhesive also has a certain degree of flame retardancy, enhancing the flame retardant and fireproof performance of the front projection screen and improving its safety.

[0072] In the embodiments of this application, step S200 involves mixing adhesive and reflective particles at a certain weight ratio (the weight percentage of reflective particles in the reflective layer is from one ten-thousandth to twenty percent). This allows the advantages of the adhesive and the reflective properties of the reflective particles to be combined into the reflective layer. The mixed adhesive and reflective particles are then applied to the surface layer to form the reflective layer, enabling the surface layer and reflective layer to adhere effectively together. This enhances the stability of the surface layer and reflective layer bonding, thereby improving the overall stability of the projection screen.

[0073] The surface layer and reflective layer formed in steps S100 and S200 are peeled off from the intermediate surface film as a whole to form a front projection screen composed of a surface layer and a reflective layer. Here, the surface layer and reflective layer can be composed of a single layer or a multi-layer composite structure.

[0074] As a further explanation, the curing temperature in step S100 is 60℃~160℃, and the curing temperature in step S200 is also 60℃~160℃. This avoids excessively low curing temperatures, which would result in excessively long curing times, and excessively high curing temperatures, which would affect the structure of the surface layer and reflective layer. Here, the curing time can be controlled by adjusting the curing temperature, keeping the time of each process segment within a certain range, thereby controlling the overall production process time. To better control the time of each process segment, given a fixed thickness of the surface layer and reflective layer, the following rule is adopted: for every 10℃ decrease in curing temperature, the curing time is doubled.

[0075] The front projection screen produced by this method has a simple structure, strong resistance to aging and ultraviolet radiation, and good stability, which effectively improves the reliability and economic efficiency of the front projection screen.

[0076] Example 2

[0077] Figure 3 This is a schematic diagram of the front projection screen structure of Embodiment 2 of this application; Figure 4 yes Figure 3 A simplified diagram of the front projection screen manufacturing process; Figure 5 yes Figure 4 Simplified diagram of step S100; Figure 6 yes Figure 4 Simplified diagram of step S200; Figure 7 yes Figure 4 Simplified diagram of step S300; Figure 8 yes Figure 4 Simplified diagram of steps S400.

[0078] The difference between the front projection screen of Embodiment 2 and Embodiment 1 is that, in addition to the surface layer and reflective layer 2000, it also includes an adhesive layer 3000 and a base fabric layer 4000, which are sequentially disposed on the side of the reflective layer 2000 away from the surface layer.

[0079] In the embodiments of this application, by setting the adhesive layer 3000 and the base fabric layer 4000, the requirements of the front projection screen formed by the surface layer and the reflective layer 2000 on the installation wall are reduced, making the manufactured front projection screen more universal.

[0080] In the embodiments of this application, the adhesive layer 3000 comprises a silicone material, and the thickness of the adhesive layer is 50 micrometers to 100 micrometers. Using silicone material in the adhesive layer 3000 allows it to possess a certain degree of elasticity, which helps maintain the elasticity and rollability of the projection screen. Controlling the thickness of the adhesive layer 3000 to 50 micrometers to 100 micrometers avoids the situation where the adhesive layer 3000 is too thin, resulting in insufficient adhesive force for the base fabric layer 4000. This effectively controls the adhesive force of the adhesive layer 3000, ensuring the bonding stability between the reflective layer 2000 and the base fabric layer 4000, and enhancing the stability of the projection screen; it also avoids the situation where the adhesive layer 3000 is too thick, resulting in excessive adhesive force and material waste.

[0081] As a further explanation, color / pigment can be added to the adhesive layer 3000 to selectively absorb light, improve the contrast of the front projection screen, and thus enhance the imaging display effect of the front projection screen.

[0082] In the embodiments of this application, the base fabric layer 4000 can limit the elasticity of the reflective layer 2000 and the surface layer within a certain range, avoiding severe local deformation of the front projection screen during the rolling and unfolding process, thereby enhancing the stability of the front projection screen. With the base fabric layer 4000 and the adhesive layer 3000 simultaneously provided, the wrinkle resistance, stiffness, and surface flatness of the front projection screen can also be enhanced.

[0083] In the embodiments of this application, the material of the base fabric layer 4000 can be natural fibers, chemical fibers, and blended fibers. To maintain stable performance and high cost-effectiveness, chemical fibers are selected as the material of the base fabric layer 4000.

[0084] In the embodiments of this application, the thickness of the base fabric layer 4000 can be 30 micrometers to 1000 micrometers. By controlling the thickness of the adhesive layer 3000 and the base fabric layer 4000, the thickness of the front projection screen can be controlled to a certain extent, avoiding the problem of an excessively thick front projection screen, resulting in a heavier overall weight and higher installation and transportation costs.

[0085] As a further option, the thickness of the base fabric layer 4000 can be controlled between 30 micrometers and 800 micrometers. Even better, the thickness of the base fabric layer 4000 can be controlled between 100 micrometers and 400 micrometers, which makes it easier to control the thickness of the entire front projection screen.

[0086] The difference between the method for manufacturing the front projection screen in Example 2 and that in Example 1 is as follows:

[0087] Before demolding, the production method for a front projection screen also includes:

[0088] S300, Adhesive layer coating: Apply a silicone material with adhesive properties to the reflective layer, smooth it to form adhesive layer 3000, and prepare the base fabric;

[0089] S400, Composite Curing: The base fabric is laminated onto the adhesive layer 3000 and cured to form the base fabric layer 4000.

[0090] In the embodiments of this application, an adhesive layer 3000 and a base fabric layer 4000 are provided on the surface layer and the reflective layer 2000. The adhesive layer 3000 serves to connect the base fabric layer 4000 and the reflective layer 2000. The elasticity of the reflective layer 2000 and the surface layer is controlled and limited within a certain range by the base fabric layer 4000, thereby enhancing the stability of the front projection screen.

[0091] Here, the curing temperature of step S400 can be controlled between 60℃ and 160℃. In this way, by controlling the curing temperature, the curing time can be controlled, thereby controlling the time of the entire manufacturing process and ensuring the orderly and stable progress of the entire process.

[0092] The front projection screen produced by the above method has a simple structure, strong resistance to aging and ultraviolet radiation, and good stability, effectively improving the reliability and cost-effectiveness of the front projection screen. Furthermore, the front projection screen containing a 4000 base fabric layer has wider installation versatility and a broader range of applications.

[0093] Those skilled in the art will recognize that the embodiments described herein are intended to help the reader understand the principles of the invention, and should be understood that the scope of protection of the invention is not limited to such specific statements and embodiments. Those skilled in the art can make various other specific modifications and combinations based on the technical teachings disclosed in this invention without departing from the spirit of the invention, and these modifications and combinations are still within the scope of protection of this invention.

Claims

1. A front projection screen comprising a surface layer and a reflective layer, the surface layer being a microstructured layer, characterized in that, The microstructure layer is non-smooth on the side away from the reflective layer; the microstructure layer is formed by surface glue, and the thickness of the microstructure layer is 10 microns to 500 microns; the reflective layer is formed by uniform mixing of adhesive glue and reflective particles, and the weight percentage of the reflective particles in the reflective layer is 0.01% to 20%.

2. The front projection screen of claim 1, wherein, The surface glue contains silicone polymer, and the weight percentage of the silicone polymer in the surface glue is not less than 70%.

3. The front projection screen of claim 2, wherein, The surface glue further contains surface glue filler, and the weight percentage of the surface glue filler in the surface glue is not more than 30%.

4. The front projection screen of claim 1, wherein, The reflective layer is formed by uniform mixing of the adhesive glue and the reflective particles.

5. The front projection screen of claim 1, wherein, The reflective particles are not completely the same in particle size.

6. The front projection screen of claim 1, wherein, The reflective particles are 0.05 microns to 10 microns in particle size.

7. The front projection screen of claim 1, wherein, The adhesive layer and the base cloth layer are sequentially arranged on the side of the reflective layer away from the microstructure layer; the adhesive layer contains silicone glue, and the thickness of the adhesive layer is 50 microns to 100 microns; the thickness of the base cloth layer is 30 microns to 1000 microns.

8. A method of producing a front projection screen, characterized by The method comprises the following steps: S100, manufacturing a surface layer: designing an optical microstructure through optical simulation, manufacturing a roller mold with the optical microstructure, manufacturing an intermediate surface film containing the optical microstructure based on the roller mold, applying surface glue on the intermediate surface film, smoothing, curing, and forming a surface layer with a thickness of 10 microns to 500 microns; S200, manufacturing a reflective layer: mixing adhesive glue and reflective particles, applying on the surface layer, and curing to form a reflective layer, and the weight percentage of the reflective particles in the reflective layer is 0.01% to 20%; The surface layer and the reflective layer are formed by layering through the foregoing steps, and the intermediate surface film is separated to form a front projection screen.

9. The method of manufacturing according to claim 8, wherein, The curing temperature in step S100 is 60°C to 160°C, and the curing temperature in step S200 is 60°C to 160°C.

10. The method of manufacturing according to claim 8, wherein, Before demolding, the method further comprises: S300, adhesive layer glue application: applying silicone glue with adhesive force on the reflective layer, smoothing to form an adhesive layer, and preparing a base cloth; S400, composite curing: combining the base cloth on the adhesive layer, curing, and forming a base cloth layer.

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