Fresnel projection curtain and roller for producing same, and methods for manufacturing and using roller

Abstract

Disclosed in the present invention are a Fresnel projection curtain and a roller for producing same, and methods for manufacturing and using the roller, aiming at overcoming the defect that an existing Fresnel curtain cannot take both a viewing angle and light concentration into consideration. The Fresnel projection curtain comprises a Fresnel structure on the back and a lateral diffusion structure on the front; the lateral diffusion structure comprises a prism structure arranged in the width direction; the prism structure is bilaterally symmetrical; and irregular convex marks are provided on the surface of the prism structure. In the present invention, by providing the lateral diffusion structure on the surface of the curtain, light that is originally generated by the Fresnel structure and converges towards the center is diffused to the left and right sides, so that a quite good viewing angle is obtained in the left-right direction.

Description

A Fresnel projection screen and roller body used for production, and manufacturing and use methods Technical Field

[0001] The present invention relates to the field of screens and their preparation, and more particularly to a Fresnel projection screen and a roller body used for its production, as well as a manufacturing and use method. Background Art

[0002] Laser TVs consist of a projector and a screen. Light from the projector reflects off the screen and is absorbed by the viewer's eyes, producing a corresponding image. This device can produce extremely high-definition images, creating a cinematic experience. Its unique advantages over OLAD and IPS have created a massive new market.

[0003] The main problem and pain point of laser TV is that since its screen passively reflects light, it has high requirements for the lighting environment and weak anti-interference ability from the external environment. The image quality will be significantly negatively affected in brighter environments.

[0004] In order to obtain a better viewing experience, the relevant technology uses a Fresnel structure to concentrate light in the screen to obtain better image quality. However, due to the characteristics of the Fresnel structure, the light concentration of the screen affects the viewing angle, resulting in a better viewing experience only in a smaller range.

[0005] Currently, there is a related technology that increases the diffuse reflection of light by setting corresponding atomization processing on the screen with a Fresnel structure, which in turn weakens the concentration of light to a certain extent, reducing the illumination and actual brightness.

[0006] Summary of the Invention

[0007] The present invention overcomes the drawbacks of existing Fresnel screens in terms of the dilemma between viewing angle and light concentration, and provides a Fresnel projection screen and a roller body used for production, as well as a manufacturing and use method. The Fresnel projection screen can diffuse the light diffusely reflected from top and bottom to the left and right, thereby taking into account both brightness and viewing angle.

[0008] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0009] A Fresnel projection screen includes a Fresnel structure arranged on the back and a lateral diffusion structure arranged on the front. The lateral diffusion structure includes a prism structure arranged along the width direction. The prism structure is bilaterally symmetrical and has irregular convex marks on the surface of the prism structure.

[0010] The screen of the present invention converges light by refraction, thereby achieving a high brightness effect. Specifically, after light is generated, it enters the prism structure from the air. Most of the light enters the screen by refraction, and then reflects inside the screen after reaching the back. During this process, the light is concentrated toward the center due to the Fresnel structure on the back. The light reaches the front from the back and is refracted again by the prism structure after reaching the critical surface between the screen and the air. During this process, it diverges to both sides, thereby expanding the viewing angle. The symmetry of the left and right sides of the prism structure means that the amount of light diverging to the left and right sides after passing through the prism structure is equal, which ensures that the visual experience obtained at the left and right symmetrical positions in front of the screen is the same. The convex marks further increase the haze and gain.

[0011] A roller body, used for processing a Fresnel laser projection screen as described above, includes a copper layer arranged on the surface of the roller body, and a recessed structure arranged along the axial direction of the roller body is provided on the copper layer. The recessed structure is bilaterally symmetrical and irregular recesses are provided on the surface of the recessed structure.

[0012] To form the aforementioned curtain, a roller is required to form the lateral diffusion structure. Specifically, this is done by rolling the roller. Since the prism structure described above is convex, a concave structure is provided on the copper layer. Since the convex structure is bilaterally symmetrical, the concave structure is also symmetrical. Similarly, to create the corresponding irregular convex marks, corresponding irregular concave marks are provided on the roller.

[0013] A method for manufacturing a roller body, for manufacturing a roller body as described above, comprising the steps of:

[0014] (1) laying a copper layer on the surface of the base roller;

[0015] (2) using a tool to carve a concave structure in the axial direction on the copper layer, wherein the concave structure is in a V-shape;

[0016] (3) Random chrome plating is performed on the surface of the recessed structure;

[0017] (4) Sandblasting is performed on the surface of the recessed structure.

[0018] The present invention provides a relatively soft copper layer on the base roller, and in step 2, recessed structures are formed on the copper layer. This step makes the roller body easier to process. A tool is fed axially and then radially fed at intervals to form a plurality of continuous recessed structures. Random chrome plating in step 3 improves haze. In step 4, sandblasting creates random pits to improve haze and gain.

[0019] Preferably, the cutting tool is a diamond cutting tool with an included angle of 110° to 130°, and the cutting tip is rounded. The cutting tool has a V-shaped cross-section. The roller is clamped and rotated axially, and the cutting tool is fed along its central axis toward the normal direction of the roller surface. The feed speed and the roller rotation speed are set according to common knowledge in the art until a V-shaped annular groove is formed on the roller surface. Upon completion, the cutting tool is withdrawn radially and then fed again after axial displacement, thereby forming a continuous annular groove.

[0020] Preferably, the R value of the blade tip radius is 50 μm. The structure ensures that enough light is emitted perpendicularly to the screen, ensuring the viewing experience of the audience facing the front.

[0021] Preferably, the distance between adjacent concave structures is less than half of the width of the concave structures. The structure avoids the adjacent concave structures from being continuous, and avoids the generation of periodic brightness changes similar to diffraction fringes.

[0022] Preferably, the chromium plating conditions are a current of 5000 mA, a time of 30 minutes, and a temperature of 35 degrees Celsius. With the above structure, the roughness of the roller surface is increased, and the haze of the product is increased.

[0023] A method for using a roller, employing the roller described above, wherein the roller transfers a concave structure on the surface of a base roller to the opposite surface of a projection screen having a Fresnel structure via UV transfer, thereby forming a lateral diffusion structure. The method utilizes the roller as a mold and performs the transfer via UV transfer, with the transfer surface located on the side of the screen facing away from the Fresnel structure.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] (1) The present invention provides a lateral diffusion structure on the surface of the screen to diffuse the light originally generated by the Fresnel structure that converges toward the center to the left and right sides, thereby achieving a very good viewing angle in the left and right directions;

[0026] (2) By providing convex marks for the lateral diffusion structure, the corresponding haze and gain are increased, thereby improving the quality of the product;

[0027] (3) The production process of the roller body for preparing the screen is simple, and the method of using the roller body is not complicated. It supports secondary processing of the Fresnel screen and is easy to add to the existing Fresnel screen production line, thereby reducing costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] FIG1 is a schematic diagram of a conventional laser TV according to the present invention;

[0029] FIG2 is a schematic diagram of roller processing of the present invention;

[0030] In the picture:

[0031] Projector 1, screen 2, Fresnel structure 3, cutter 4, recessed structure 5, chamfered corner 6, roller body 7. DETAILED DESCRIPTION

[0032] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0033] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of the present invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which the present invention belongs.

[0034] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present invention. As used herein, unless the context clearly indicates otherwise, the singular form is intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0035] In the present invention, terms such as "fixed connection," "connected," and "connection" should be interpreted broadly to mean a fixed connection, an integral connection, or a detachable connection; a direct connection or an indirect connection through an intermediary. Relevant researchers or technicians in this field may determine the specific meanings of these terms in the present invention based on specific circumstances, and they should not be construed as limitations of the present invention.

[0036] Example:

[0037] A Fresnel projection screen, shown in Figure 1, comprises a Fresnel structure 3 on the back and a lateral diffusion structure on the front. The lateral diffusion structure comprises a prism structure arranged along the width, the prism structure being bilaterally symmetrical and having irregular ridges on its surface. The front and back sides refer to the side facing the audience and projector 1 as the front, and the side facing the wall or facing away from the audience and projector 1 as the back. The screen 2 referred to in the present invention has a reflective material coated on one side of the Fresnel structure 3 to prevent light from passing through the Fresnel structure 3, instead reflecting it in a mirror-like manner.

[0038] The symmetry of the left and right sides of the prism structure ensures that the light diverges equally to the left and right sides after passing through the prism structure, resulting in the same visual experience at symmetrical positions on the left and right sides of the screen 2. The convex marks further increase the haze and gain.

[0039] The principle behind the increased viewing angle achieved by the lateral diffusion structure of screen 2 is that screen 2 of the present invention converges light through refraction, thereby achieving a high brightness effect. Specifically, after being generated, light enters the prism structure from the air. Due to the small angle between the light and the prism structure, there is less reflection, and the vast majority of the light enters screen 2 through refraction. Upon reaching the back, it is reflected within screen 2. During this process, the Fresnel structure 3 on the back converges the light toward the center. From the back, the light reaches the front and, upon reaching the interface between screen 2 and the air, it is refracted again by the prism structure, diverging to both sides, thereby expanding the viewing angle. This structure allows the light from above and below to be concentrated and then diffused to the left and right, resulting in a better viewing angle in both directions.

[0040] A method for manufacturing a roller body 7, used to manufacture a roller body 7 as described above, the manufacturing method comprising the steps of:

[0041] (1) A copper layer is laid on the surface of a base roller, the copper layer is electroplated, the base roller is placed on a lathe, the runout value of the base roller is calibrated, and the copper layer on the surface of the roller is leveled and polished;

[0042] (2) A tool 4 is used to carve a concave structure 5 on the copper layer in the axial direction, wherein the concave structure 5 is in the shape of a "V", wherein the tool 4 is a diamond tool 4 with an angle of 110° to 130°, and the tip of the tool 4 is provided with a chamfer 6; the tool 4 has a V-shaped cross section; the roller 7 is clamped and rotated in the axial direction of the roller 7, and the tool 4 is fed in the direction of its axis toward the normal direction of the surface of the roller 7, and the feed speed and the rotation speed of the roller 7 are set according to the general common sense in the field, until a V-shaped annular groove is generated on the surface of the roller 7, and after completion, the tool is withdrawn radially and the roller is rotated axially. After displacement, the knife is fed again to produce a continuous annular groove; the R value of the knife tip radius is 50 μm; the structure ensures that enough light is emitted perpendicular to the curtain 2 to ensure the viewing experience of the audience in front; the distance between adjacent concave structures 5 is less than half the width of the concave structure 5; the structure avoids the continuity of adjacent concave structures 5 and avoids the generation of periodic changes in brightness similar to diffraction stripes; (3) the surface of the concave structure 5 is randomly chrome-plated, and the chrome-plating conditions are 5000 mA current, 30 minutes time, and 35 degrees Celsius temperature; through the above structure, the roughness of the roller body 7 surface is increased, and the haze of the product is increased;

[0043] (4) Sandblasting is performed on the surface of the recessed structure 5. The sandblasting is performed using fine sand made of glass beads, and the size of the sandblasting is 40-100 μm.

[0044] In some possible embodiments, the depth of the roller 7 varies at various points along its circumference. A specific point is designated as the 0-degree point. From 0 to 360 degrees, the depth varies according to a sinusoidal function, with a period of 600 to 1200 μm and an amplitude of ±2 μm. The circumference of the roller 7's cross section adapts to the length of the screen 2. This structure ensures that the screen 2 formed by rolling the roller 7 along its length, starting from the 0-degree point, has a smaller protrusion at the top and bottom ends and a larger protrusion in the middle. This structure reduces the amount of light emitted from the top and bottom ends of the screen 2, thereby increasing brightness at other locations.

[0045] A roller body 7, as shown in Figure 2, is used to process a Fresnel laser projection screen 2 as described above, including a copper layer provided on the surface of the roller body 7, and a recessed structure 5 provided on the copper layer along the axial direction of the roller body 7. The recessed structure 5 is bilaterally symmetrical and has irregular recesses on its surface.

[0046] To form the aforementioned screen 2, a roller 7 is required to form the lateral diffusion structure. Specifically, this is achieved by rolling the roller 7. Since the prism structure described above is convex, a concave structure 5 is provided on the copper layer. Since the convex structure is bilaterally symmetrical, the concave structure 5 is also symmetrical. Similarly, to create the corresponding irregular convex marks, corresponding irregular concavities are provided on the roller 7.

[0047] The present invention provides a relatively soft copper layer on the base roller, and in step 2, the recessed structures 5 are formed on the copper layer. This step makes machining the roller body 7 easier. A tool 4 is fed axially and then radially fed at intervals to form a plurality of continuous recessed structures 5. Random chrome plating in step 3 improves haze. In step 4, sandblasting creates random pits to improve haze and gain.

[0048] A method for using a roller 7, using the roller 7 described above, wherein the roller 7 transfers the concave structure 5 on the surface of the base roller to the opposite surface of the projection screen 2 having the Fresnel structure 3 via UV transfer, thereby forming a lateral diffusion structure. The method uses the roller as a mold and performs the transfer via UV transfer, with the transfer surface located on the side of the projection screen 2 facing away from the Fresnel structure 3.

[0049] The following is an example analysis using specific practical operations.

[0050] Example 1:

[0051] A method for manufacturing a roller body, the manufacturing method comprising the steps of:

[0052] (1) laying a copper layer on the surface of the base roller;

[0053] (2) using a tool 4 to carve a concave structure 5 in the axial direction on the copper layer, wherein the concave structure 5 is in a V-shape, wherein the R value of the tool 4 is 50 μm, the angle between the two edge surfaces of the tool 4 forming the V-shape is 120°, the pitch of adjacent concave structures 5 in the axial direction is 120 μm, and the feed depth is 11 μm;

[0054] (3) performing random chrome plating on the surface of the recessed structure 5;

[0055] (4) Sandblasting is performed on the surface of the recessed structure 5, and the diameter of the sandblasting is 40 μm.

[0056] Example 2:

[0057] A method for manufacturing a roller body, the manufacturing method comprising the steps of:

[0058] (1) laying a copper layer on the surface of the base roller;

[0059] (2) using a tool 4 to carve a concave structure 5 in the axial direction on the copper layer, wherein the concave structure 5 is in a V-shape, wherein the R value of the tool 4 is 50 μm, the angle between the two edge surfaces of the tool 4 forming the V-shape is 120°, the pitch of adjacent concave structures 5 in the axial direction is 120 μm, and the feed depth is 11 μm;

[0060] (3) performing random chrome plating on the surface of the recessed structure 5;

[0061] (4) Sandblasting is performed on the surface of the recessed structure 5, and the diameter of the sandblasting is 80 μm.

[0062] Example 3:

[0063] A method for manufacturing a roller body, the manufacturing method comprising the steps of:

[0064] (1) laying a copper layer on the surface of the base roller;

[0065] (2) using a tool 4 to carve a concave structure 5 in the axial direction on the copper layer, wherein the concave structure 5 is in a V-shape, wherein the R value of the tool 4 is 50 μm, the angle between the two edge surfaces of the tool 4 forming the V-shape is 120°, the pitch of adjacent concave structures 5 in the axial direction is 150 μm, and the feed depth is 15 μm;

[0066] (3) performing random chrome plating on the surface of the recessed structure 5;

[0067] (4) Sandblasting is performed on the surface of the recessed structure 5, and the diameter of the sandblasting is 80 μm.

[0068] Example 4:

[0069] A method for manufacturing a roller body, the manufacturing method comprising the steps of:

[0070] (1) laying a copper layer on the surface of the base roller;

[0071] (2) using a tool 4 to carve a concave structure 5 in the axial direction on the copper layer, wherein the concave structure 5 is in a V-shape, wherein the R value of the tool 4 is 50 μm, the angle between the two edge surfaces of the tool 4 forming the V-shape is 120°, the pitch of adjacent concave structures 5 in the axial direction is 150 μm, and the feed depth is 18 μm;

[0072] (3) performing random chrome plating on the surface of the recessed structure 5;

[0073] (4) Sandblasting is performed on the surface of the recessed structure 5, and the diameter of the sandblasting is 100 μm.

[0074] Example 5:

[0075] A method for manufacturing a roller body, the manufacturing method comprising the steps of:

[0076] (1) laying a copper layer on the surface of the base roller;

[0077] (2) using a tool 4 to carve a concave structure 5 in the axial direction on the copper layer, wherein the concave structure 5 is in a V-shape, wherein the R value of the tool 4 is 50 μm, the angle between the two edge surfaces of the tool 4 forming the V-shape is 120°, the pitch of adjacent concave structures 5 in the axial direction is 150 μm, and the feed depth is 13 μm;

[0078] (3) performing random chrome plating on the surface of the recessed structure 5;

[0079] (4) Sandblasting is performed on the surface of the recessed structure 5, and the diameter of the sandblasting is 80 μm.

[0080] Comparative Example:

[0081] For existing screens with Fresnel structures 3 located on the back, a uniform atomization treatment is performed on the front side, utilizing diffuse reflection to increase the scattering of light reflected by the projection screen 2, thereby improving the viewing angle of the projected image. The atomization treatment includes, but is not limited to, transferring the irregular raised structure on the surface from a mold having irregular small pits.

[0082] Actual effect:

[0083] Wherein, the gain detection method is:

[0084] a) Turn on the standard light source or input the white field signal;

[0085] b) Use an illuminance meter to measure the illuminance at the center point;

[0086] c) Use a luminance meter to measure the brightness of the center point of the screen at a distance of three times the height of the screen in the normal direction of the center point of the screen;

[0087] d) Calculate the gain according to formula (1);

[0088] G—screen gain;

[0089] L—center point brightness;

[0090] E—Center point illuminance.

[0091] The horizontal viewing angle is detected as follows:

[0092] a) Turn on the standard light source or input the white field signal;

[0093] b) Measure the gain at the center of the screen according to the above provisions;

[0094] c) Keep the distance between the luminance meter and the center point of the screen unchanged, and rotate the luminance meter to the left in the horizontal plane until the brightness drops to 50% of the normal direction. Record the rotation angle of the luminance meter at this time;

[0095] d) Repeat step c) to the right;

[0096] e) Calculate the horizontal half-gain viewing angle according to formula (2). θ=θ1+θ2#(2)

[0097] Where θ1 is the left angle and θ2 is the right angle.

[0098] The above-described embodiments are only preferred solutions of the present invention and are not intended to limit the present invention in any form. Other variations and modifications are possible without exceeding the technical solutions described in the claims.

Claims

1. A Fresnel projection screen, characterized in that: It comprises a Fresnel structure arranged on the back and a lateral diffusion structure arranged on the front. The lateral diffusion structure comprises a prism structure arranged along the width direction. The prism structure is bilaterally symmetrical and irregular convex marks are arranged on the surface of the prism structure.

2. A roller body, characterized in that: A Fresnel laser projection screen for processing as claimed in claim 1, comprising a copper layer arranged on the surface of a roller body, wherein the copper layer is provided with a recessed structure arranged along the axial direction of the roller body, wherein the recessed structure is bilaterally symmetrical and irregular recesses are arranged on the surface of the recessed structure.

3. A method for manufacturing a roller body, characterized in that: For manufacturing a roller body as claimed in claim 2, the manufacturing method comprises the steps of: (1) Arranging a copper layer on the surface of the base roller; (2) using a tool to carve a concave structure on the copper layer along the axial direction, wherein the concave structure is in a "V" shape; (3) Random chrome plating is performed on the surface of the recessed structure; (4) Sandblasting is performed on the surface of the recessed structure.

4. A method for manufacturing a roller body according to claim 3, characterized in that: The tool is a diamond tool with an included angle of 110° to 130°, and the tip of the tool is provided with a rounded corner.

5. A method for manufacturing a roller body according to claim 4, characterized in that: The R value of the knife tip radius is 50um.

6. The method for manufacturing a roller body according to claim 3, characterized in that: The distance between adjacent recessed structures is less than half of the width of the recessed structures.

7. The method for manufacturing a roller body according to claim 3, characterized in that: The chromium plating conditions are: current 5000 mA, time 30 minutes, temperature 35 degrees Celsius.

8. A method for using a roller, characterized in that: The roller body comprises the roller body as claimed in claim 2, wherein the roller body transfers the concave structure on the surface of the base roller to the opposite surface of the projection screen having the Fresnel structure by UV transfer and forms a lateral diffusion structure.

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