Projection screen, preparation method therefor, projection system and vehicle

Abstract

A projection screen (10), a preparation method for the projection screen (10), a projection system and a vehicle. The projection screen (10) comprises a black base fabric layer (11), a black flexible undercoating layer (12) and a white flexible surface layer (13) which are sequentially stacked; the black base fabric layer (11) comprises a loop structure, a weft insertion structure and a fabric stiffening agent; the loop structure is formed by weaving a ground yarn (11a); the weft insertion structure is formed from a weft insertion yarn (11b) inserted in the weft direction into the loop structure; the fabric stiffening agent fills gaps between the ground yarn (11a) and the weft insertion yarn (11b); the ground yarn (11a) is made of polyester and a fiber reinforced material; and the weft insertion yarn (11b) is made of glass fibers.

Description

Projection screen, preparation method thereof, projection system and vehicle TECHNICAL FIELD

[0001] The present application relates to the field of optical technology, in particular to a projection screen, a preparation method thereof, a projection system and a vehicle. BACKGROUND

[0002] With the development of automobile intelligence, the vehicle-mounted projector becomes a more and more popular function in modern cars, and the vehicle-mounted projector provides more entertainment choices for people traveling. The vehicle-mounted projector is installed at the top of the car, and is matched with a dedicated vehicle-mounted projector screen, so that people can enjoy the comfortable experience of large-screen viewing in the car. Because of the high reliability (high temperature 105℃, low temperature-40℃, double 85 high temperature and high humidity) and long durability (10 years) required by vehicle-mounted products, the current conventional consumer electronics type projection screen cannot meet the requirements.

[0003] Therefore, it is urgent to develop a new screen material to meet the use requirements of the vehicle-mounted projection screen. SUMMARY

[0004] The first aspect of the present application provides a projection screen. The projection screen comprises a black base cloth layer, a black flexible primer layer and a white flexible surface layer which are sequentially stacked. The black base cloth layer comprises a loop structure, a weft filling structure and a fabric stiffening agent. The loop structure is knitted by ground yarn. The weft filling structure is formed by weft yarns filled into the loop structure along the weft direction. The fabric stiffening agent is filled in the gap between the ground yarn and the weft yarn. The material of the ground yarn comprises polyester and fiber reinforced material. The material of the weft yarn comprises glass fiber.

[0005] In the projection screen of the first aspect of the present application, the black base cloth layer comprises the loop structure knitted by the ground yarn, which is conducive to increasing the longitudinal strength of the black base cloth layer and enhancing the structural stability of the black base cloth layer. At the same time, the material of the ground yarn comprises fiber reinforced material, which can effectively reduce the deformation of the fabric in a wide temperature range and effectively ensure the dimensional stability of the black base cloth layer, so that even under the action of relatively large gravity in the longitudinal direction under high temperature, the projection screen can still maintain a small deformation amount.

[0006] In addition, the black base cloth layer includes a weft insertion structure formed by weft insertion yarns inserted into the loop structure along the weft direction, which is conducive to increasing the support force in the transverse direction of the projection screen, and improving the problem of the lower modulus of the conventional fabric material and the lower modulus of the surface selected silicone and other lower modulus elastic materials, which causes the lower edge of the large width to be easily rolled in priority, thereby effectively increasing the effective display area. At the same time, the material of the weft insertion yarns includes glass fiber, which can effectively improve the anti-shake characteristics of the projection screen. It should be noted that although the bending resistance of glass fiber is low, the projection screen is rolled along the longitudinal direction (or the direction perpendicular to the weft direction), so the use of glass fiber for weft insertion yarns does not affect the rolling characteristics of the projection screen. In addition, the use of glass fiber as the main body of the weft insertion yarns can effectively reduce the deformation of the fabric in a wide temperature range, and effectively ensure the dimensional stability of the black base cloth layer.

[0007] In addition, the black base cloth layer also includes a fabric stiffening agent filled in the gap between the ground yarns and the weft insertion yarns, which is conducive to improving the stiffness of the black base cloth layer, effectively improving the bending strength of the fabric in the black base cloth layer, increasing the overall modulus of the black base cloth layer, and enhancing the overall support of the projection screen. The hardness increases, the vibration spreads quickly, the anti-vibration characteristics are enhanced, and the requirements for normal use of the projection screen during the bumpy vibration of the car driving process can be met. At the same time, the in-plane stress distribution of the entire projection screen is uniform when the projection screen is unfolded, thereby ensuring the surface flatness of the projection screen and effectively improving the phenomenon of edge curling of the projection screen under the condition of large width.

[0008] In addition, the black flexible primer layer and the black base cloth layer can form a double-layer black background structure, further reducing the light transmittance of the projection screen, the screen gain is 1.0, and the brightness of the projection screen is improved, which is conducive to realizing high brightness and high contrast display effect. Moreover, the modulus of the black flexible primer layer is relatively low, and the elastic range is large, so although the modulus difference between the black flexible primer layer and the black base cloth layer will generate additional transverse force and radial force, the deformation formed by the transverse force and the radial force is within the elastic range of the black flexible primer layer, and will not cause additional plastic deformation of the projection screen, so it will not cause the finished screen to produce wrinkles after installation and overall structure fixation.

[0009] In addition, the white flexible surface layer has a certain flexibility, which meets the high reliability requirements of vehicle-mounted materials. Within the entire environmental requirement range, the modulus of the projection screen changes little, which can effectively avoid the phenomenon that the conventional screen uses traditional plastic materials such as polyvinyl chloride (PVC) to harden and increase the modulus at low temperature, and cannot be normally opened, and effectively avoids the wrinkles caused by the deformation of the conventional screen using traditional plastic materials such as PVC at high temperature.

[0010] In summary, the comprehensive arrangement of the structure and material of the black base cloth layer, the black flexible primer layer and the white flexible surface layer in the projection curtain is conducive to meeting the requirements of the projection curtain in the harsh use environment of the vehicle-mounted curtain.

[0011] It should be noted that in the embodiments of the present application, "black" refers to any material or surface with good light absorption and low light transmission, not just color. In other words, in the embodiments of the present application, "black" not only includes materials or surfaces that appear visually black, but also materials or surfaces that exhibit similar black characteristics optically, which can absorb most of the incident light and reflect or transmit little incident light, thus appearing dark or even close to black in vision.

[0012] Similarly, in the embodiments of the present application, "white" refers to any material or surface with high reflectivity and high scattering, not just color. In other words, in the embodiments of the present application, "white" not only includes materials or surfaces that appear visually white, but also materials or surfaces that exhibit similar white characteristics optically, which can reflect and scatter most of the incident light, thus appearing white or close to white in vision.

[0013] The second aspect of the present application provides a preparation method of a projection curtain, comprising:

[0014] coating on the carrier film to form an un-cured white flexible surface layer;

[0015] coating on the un-cured white flexible surface layer to form an un-cured black flexible primer layer;

[0016] cold-pressing the side of the un-cured black flexible primer layer away from the un-cured white flexible surface layer with a black base cloth layer, the black base cloth layer comprising a loop structure, a weft insertion structure and a fabric stiffener, the loop structure being woven from ground yarn, the weft insertion structure being formed by weft insertion yarn inserted into the loop structure along the weft direction, the fabric stiffener being filled in the gap between the ground yarn and the weft insertion yarn, the material of the ground yarn comprising polyester and fiber reinforced material, the material of the weft insertion yarn comprising glass fiber; and

[0017] high-temperature curing the stack of the black base cloth layer, the un-cured black flexible primer layer and the un-cured white flexible surface layer to obtain the projection curtain.

[0018] The preparation method of the projection curtain of the second aspect of the present application has at least the same advantages as the projection curtain of the first aspect of the present application, and will not be repeated here.

[0019] Further, in the preparation method of the projection screen according to the second aspect of the present application, the white flexible surface layer is formed by coating on the carrier film, wherein the surface flatness of the carrier film is high, and the contact surface between the white flexible surface layer and the carrier film is the appearance surface of the projection screen, so that the flatness of the appearance surface of the projection screen can be effectively improved. In addition, the black flexible primer layer is directly formed on the surface of the white flexible surface layer by coating, so that the bonding layer between the black flexible primer layer and the white flexible surface layer can be reduced, thereby facilitating the reduction of the overall thickness of the projection screen, and the space can be effectively saved after the projection screen is rolled up. Further, the white flexible surface layer and the black flexible primer layer are directly cold-pressed together with the black base cloth layer before maturation, and then high-temperature curing treatment is performed, so that the adhesion between the white flexible surface layer, the black flexible primer layer and the black base cloth layer is stronger, the delamination or peeling phenomenon between the layers due to different moduli can be effectively avoided, and the surface flatness of the projection screen can be further improved. Specifically, the process of high-temperature curing of the above-mentioned stack is equivalent to heat treatment of the black base cloth layer, which can effectively release the internal stress between the layers and reduce the problem of edge curling of the obtained projection screen.

[0020] The third aspect of the present application provides a preparation method of a projection screen, which comprises:

[0021] coating a primer material for forming a black flexible primer layer on the carrier film;

[0022] pre-curing the primer material;

[0023] forming a wire grid structure on the pre-cured primer material, the wire grid structure comprising a bonding surface and projection surfaces and non-projection surfaces arranged alternately opposite to the bonding surface;

[0024] fully curing the primer material to obtain a black flexible primer layer;

[0025] forming a white flexible surface layer on the projection surfaces of the black flexible primer layer by using a mask and spraying process; and

[0026] bonding the side of the black flexible primer layer away from the white flexible surface layer with a black base cloth layer to obtain a projection screen; the black base cloth layer comprises a loop structure, a weft filling structure and a fabric stiffening agent, the loop structure is knitted by ground yarn, the weft filling structure is formed by weft yarns inserted into the loop structure along the weft direction, and the fabric stiffening agent is filled in the gap between the ground yarn and the weft yarns, the material of the ground yarn comprises polyester and fiber reinforced material, and the material of the weft yarns comprises glass fiber.

[0027] The preparation method of the projection screen according to the third aspect of the present application has at least the same advantages as the projection screen according to the first aspect of the present application, and will not be described again.

[0028] The fourth aspect of the present application provides a preparation method of a projection screen, which comprises the following steps:

[0029] coating a base coating material for forming a black flexible base coating layer on the carrier film;

[0030] completely curing the base coating material to obtain the black flexible base coating layer;

[0031] coating a surface material for forming a white flexible surface layer on the black flexible base coating layer;

[0032] semi-curing the surface material;

[0033] forming a Fresnel structure on the semi-cured surface material, the Fresnel structure comprising a plurality of microstructure units arranged outwardly in sequence based on the same center;

[0034] completely curing the surface material to obtain the white flexible surface layer; and

[0035] attaching a side of the black flexible base coating layer, which is away from the white flexible surface layer, to a black base cloth layer to obtain the projection screen; the black base cloth layer comprises a loop structure, a weft insertion structure and a fabric stiffener, the loop structure is knitted by ground yarns, the weft insertion structure is formed by weft insertion yarns inserted into the loop structure along the weft direction, and the fabric stiffener is filled in the gap between the ground yarns and the weft insertion yarns, the material of the ground yarns comprises polyester and fiber reinforced material, and the material of the weft insertion yarns comprises glass fiber.

[0036] The preparation method of the projection screen of the fourth aspect of the present application has at least the same advantages as the projection screen of the first aspect of the present application, and will not be described again.

[0037] The fifth aspect of the present application provides a projection system, which comprises the projection screen of the first aspect of the present application and a projector for projecting image light to the projection screen.

[0038] The projection system of the fifth aspect of the present application has at least the same advantages as the projection screen of the first aspect of the present application, and will not be described again.

[0039] The sixth aspect of the present application provides a vehicle, which comprises a vehicle body and the projection system of the fifth aspect of the present application mounted on the vehicle body.

[0040] The vehicle of the sixth aspect of the present application has at least the same advantages as the projection system of the fifth aspect of the present application, and will not be described again. BRIEF DESCRIPTION OF DRAWINGS

[0041] FIG. 1 is a structural schematic diagram of the projection screen of the first embodiment of the present application.

[0042] FIG. 2 is a loop structure diagram of the black base cloth layer in FIG. 1.

[0043] Fig. 3 is a flow chart of a preparation method of the projection screen according to the first embodiment of the present application.

[0044] Fig. 4 is a structural schematic diagram of the projection screen according to the second embodiment of the present application.

[0045] Fig. 5 is a flow chart of a preparation method of the projection screen according to the second embodiment of the present application.

[0046] Fig. 6 is a structural schematic diagram of the projection screen according to the third embodiment of the present application.

[0047] Fig. 7 is a flow chart of a preparation method of the projection screen according to the third embodiment of the present application.

[0048] Main element symbol explanation: projection screen 10, 20, 30 black base cloth layer 11, 21, 31 ground yarn 11a weft yarn 11b weft direction D1 warp direction D2 gap G black flexible primer layer 12, 22, 32 wire grid structure 22a fitting surface 221 projection surface 222 non-projection surface 223 white flexible surface layer 13, 23, 33 Fresnel structure 33a microstructure unit 331 The following specific embodiments will further illustrate the present application in conjunction with the above figures. Specific embodiments

[0049] Because of the high reliability (high temperature 105℃, low temperature -40℃, double 85 high temperature and high humidity) required by the vehicle-mounted product, long durability (10 years) and other use requirements, the current conventional consumer electronics type projection screen cannot meet the requirements. Specifically, the consumer electronics screen is mostly a soft white screen. The soft white screen is mostly made by hot pressing or pasting the PVC coating layer on the fabric base cloth, which has the following problems: first, the soft white screen is easy to harden at low temperature, which causes the screen to be unable to be normally opened in the rolled state. Moreover, the soft white screen is easy to produce stress relaxation and has large size change at high temperature, thereby causing the screen material to change in size and produce wrinkles. When the projected content is irradiated to the wrinkled surface, the projected content becomes blurred, which affects the projection effect and user experience. Second, the conventional consumer electronics screen material usually has a single layer thickness of 0.9mm-2.0mm due to the manufacturing process, which occupies a large space when the screen is rolled up, and a large space needs to be reserved in the structural design. Therefore, the conventional consumer electronics screen cannot meet the requirements of miniaturization and light weight of the current automotive interior products. Third, the consumer electronics screen uses a flexible part material such as silicone as the coating layer, which can be used in a wide temperature range, but the elastic material is relatively soft and lacks support, and the bottom fabric structure needs to be optimized to meet the demand that the screen can still be normally used under the vibration condition during vehicle driving. Therefore, it is urgent to develop new screen materials and / or processes to improve the use environment of the vehicle-mounted product compared with the conventional indoor use projection screen. At the same time, the thickness of the screen is further reduced, the occupied volume of the screen after rolling up is reduced, the anti-staining property, chemical corrosion resistance and other properties are improved, and the projection picture quality is improved.

[0050] Fig. 1 is a structural schematic diagram of a projection screen according to a first embodiment of the present application. The projection screen 10 is mainly used in a vehicle-mounted projection system, but is not limited thereto. As shown in Fig. 1, the projection screen 10 includes a black base cloth layer 11, a black flexible bottom coating layer 12 and a white flexible surface layer 13 which are sequentially stacked. In use, the white flexible surface layer 13 is the side closest to the viewer, or in other words, the side on which the white flexible surface layer 13 is located is the side of the projection screen 10 for receiving the projected light. That is, along the direction of incidence of the projected light, the white flexible surface layer 13, the black flexible bottom coating layer 12 and the black base cloth layer 11 are sequentially arranged. The black base cloth layer 11 is the main support carrier of the projection screen 10 and is used to absorb ambient light. The black flexible bottom coating layer 12 is used to form a double-layer black background structure with the black base cloth layer 11 to effectively reduce the light transmission phenomenon of the projection screen. The white flexible surface layer 13 is the surface layer of the projection screen 10, and the white flexible surface layer 13 can be used to receive and reflect the projected light to the viewer.

[0051] Fig. 2 is a loop structure diagram of the black base cloth layer in Fig. 1. As shown in Fig. 2, the black base cloth layer 11 includes ground yarns 11a and weft yarns 11b. The ground yarns 11a are woven to form a loop structure. The weft yarns 11b are inserted into the loop structure along the weft direction D1 to form a weft structure. That is, the black base cloth layer 11 is a fabric mainly including a loop structure and a weft structure. Specifically, a plurality of weft yarns 11b are distributed along the warp direction D2 at intervals. Each weft yarn 11b extends along the weft direction D1 and is arranged in the loop structure formed by the ground yarns 11a, and each weft yarn 11b is alternately arranged above and below the loop structure formed by the ground yarns 11a.

[0052] It should be noted that the warp direction D2 is the winding direction of the projection screen 10, and the weft direction D1 is perpendicular to the warp direction D2. In the embodiment shown in Fig. 1, the projection screen 10 is substantially rectangular, and the weft direction D1 is the transverse direction or length direction of the projection screen 10, and the warp direction D2 is the longitudinal direction or width direction of the projection screen 10.

[0053] In some embodiments, the material of the ground yarn 11a includes polyester and fiber reinforced material. Specifically, the fiber reinforced material can be, but is not limited to, fine glass fiber. More specifically, the ground yarn 11a is mainly polyester, and a plurality of fine glass fibers are reinforced in the middle. In this way, the longitudinal (or warp direction D2) strength of the black base cloth layer 11 is increased, and the structural stability of the black base cloth layer 11 is enhanced. Moreover, the arrangement of the fiber reinforced material in the ground yarn 11a can effectively reduce the deformation of the fabric in a wide temperature range, and effectively ensure the dimensional stability of the black base cloth layer 11, so that even under the action of a relatively large gravity in the longitudinal direction, the projection screen 10 can still maintain a small deformation amount. For example, when the projection screen 10 adopts an X-shaped connection structure and a motor locking mode, the projection screen 10 needs to bear a large non-uniformly distributed gravity in the longitudinal direction. By arranging the fiber reinforced material in the ground yarn 11a, the influence of the wrinkles and deformation of the screen on the display effect caused by the lower end of the projection screen 10 under the action of a large non-uniformly distributed gravity in the unfolded state can be effectively improved.

[0054] In some embodiments, the material of the weft yarn 11b includes glass fiber. Specifically, the weft yarn 11b can be mainly black and thick glass fiber. By inserting the weft yarn 11b into the loop structure formed by the ground yarn 11a along the weft direction D1, the support force of the projection screen 10 in the transverse direction (or weft direction D1) can be increased, and the problem of the lower side edge being easily rolled in the large width when the overall material of the screen material is soft due to the use of traditional fabric material and low modulus elastic material such as silicone on the surface can be improved. In some embodiments, the projection screen 10 can control the height of the side edge roll to be within 3mm, thereby effectively increasing the effective display area.

[0055] In addition, the weft knitting method in the black base cloth layer 10 can effectively improve the in-plane support force of the projection screen 10 without significantly increasing the thickness of the fabric (which can effectively control the thickness of the fabric to be ≤0.38mm). At the same time, the use of glass fiber in the weft yarn 11b can effectively improve the anti-shaking characteristics of the projection screen 10. It should be noted that although the bending resistance of glass fiber is low, the projection screen 10 is rolled in the longitudinal direction (or warp direction D2), so the use of glass fiber in the weft yarn 11b does not affect the rolling characteristics of the projection screen 10. In addition, the use of glass fiber as the main body of the weft yarn 11b can effectively reduce the deformation of the fabric in a wide temperature range, and effectively ensure the dimensional stability of the black base cloth layer 11.

[0056] In some embodiments, the black base cloth layer 11 further comprises a fabric stiffening agent (not shown in the figure) filled in (or said to be infiltrated in) the gaps G of the ground yarn 11a and the weft yarn 11b. Specifically, the fabric stiffening agent is an environmentally friendly fabric stiffening agent, and the material of the fabric stiffening agent includes but is not limited to at least one of polyvinyl acetate, polyacrylate, and polyurethane fabric stiffening agent. The fabric stiffening agent is used to stiffen the fabric formed by the ground yarn 11a and the weft yarn 11b, which is beneficial to improve the stiffness of the fabric.

[0057] In some embodiments, the mass percentage of the fabric stiffening agent in the black base cloth layer 11 is about 3% to 4%. Alternatively, the mass ratio of the fabric stiffening agent to the fabric formed by the ground yarn 11a and the weft yarn 11b is about 1:26. In this way, by adjusting the fabric density (gram weight) and the use ratio of the stiffening agent, the bending strength of the fabric can be effectively improved, the overall modulus of the black base cloth layer 11 is improved, the overall supportability of the projection screen 10 is enhanced, the hardness is increased, the vibration is quickly dissipated (within 5s), and the anti-vibration performance is enhanced. Specifically, the projection screen 10 is used in cooperation with the X-shaped connection structure, which can meet the requirements of normal use of the projection in the process of automobile driving under the condition of vibration caused by bumps. At the same time, when the projection screen 10 is fully expanded, the in-plane stress distribution is uniform, thereby ensuring the surface flatness of the projection screen 10, improving the anti-shaking performance of the finished screen, and effectively improving the side edge curling phenomenon of the projection screen 10 under the condition of large width.

[0058] In some embodiments, the thickness of the black base cloth layer 11 is 0.35mm to 0.40mm (such as 0.35mm, 0.37mm, 0.38mm, 0.39mm, 0.40mm, etc.). That is, the black base cloth layer 11 is formed by setting the ground yarn 11a mainly composed of polyester and fiber reinforced material to form a loop structure, the weft yarn 11b mainly composed of glass fiber to form a weft structure, and the fabric stiffening agent (such as acrylic fabric stiffening agent) is infiltrated into the gaps G between the ground yarn 11a, the gaps G between the weft yarn 11b, and the gaps G between the ground yarn 11a and the weft yarn 11b by using different processes. Under the premise that the thickness of the black base cloth layer 11 is controlled to be 0.35mm to 0.40mm, the structural stability and transverse support strength of the black base cloth layer 11 are ensured, thereby ensuring the flatness of the screen and the anti-shaking effect. Specifically, the smaller the thickness of the black base cloth layer 11, the more conducive to reducing the occupied volume of the projection screen 10 after being rolled up, and the larger the thickness of the black base cloth layer 11, the more conducive to reducing the light transmittance of the projection screen 10, and improving the brightness and contrast of the projection screen 10.

[0059] In some embodiments, the material of the black flexible bottom coating layer 12 includes, but is not limited to, one of black silicone, thermoplastic polyurethane elastomer (TPU), thermoplastic elastomer (TPE), thermoplastic polyolefin elastomer (TPO), thermoplastic polyester elastomer (TPEE), and the like.

[0060] Specifically, the black flexible bottom coating layer 12 can effectively reduce the light transmission of the projection screen 10. The black flexible bottom coating layer 12 and the black base cloth layer 11 can form a double-layer black background structure, which can further reduce the light transmission of the projection screen 10, screen gain 1.0, improve the brightness of the projection screen 10, and facilitate the realization of high-brightness and high-contrast display effect. In addition, the modulus of the black flexible bottom coating layer 12 is relatively low, and the elastic range is large. Therefore, although the modulus difference between the black flexible bottom coating layer 12 and the black base cloth layer 11 will generate additional transverse force and radial force in the entire use temperature range, the deformation formed by the transverse force and the radial force is within the elastic range of the black flexible bottom coating layer 12, and will not cause additional plastic deformation of the projection screen 10, so as to avoid the wrinkle phenomenon of the finished screen after installation and overall structure fixation.

[0061] In some embodiments, the thickness of the black flexible bottom coating layer 12 is less than or equal to 0.10 mm (such as 0.10 mm, 0.09 mm, 0.08 mm, 0.07 mm, 0.06 mm, 0.05 mm, etc.). The smaller the thickness of the black flexible bottom coating layer 12, the more conducive to reducing the occupied volume of the projection screen 10 after winding, and the greater the thickness of the black flexible bottom coating layer 12, the more conducive to reducing the light transmission of the projection screen 10 and improving the brightness and contrast of the projection screen 10.

[0062] In some embodiments, the material of the white flexible surface layer 13 includes, but is not limited to, one of white silicone, TPU, TPE, TPO, TPEE, and the like.

[0063] Specifically, when the material of the white flexible surface layer 13 adopts white silica gel, due to the stable nature of the silica gel material itself, the use requirement of high reliability of the vehicle-mounted material is met, and thus the modulus of the projection screen 10 changes little within the entire environmental requirement range, which can effectively avoid the phenomenon that the traditional screen using traditional plastic materials such as PVC hardens and the modulus increases at low temperature, and the screen cannot be normally opened, and effectively avoid the problem of wrinkles generated by the deformation of the traditional screen using traditional plastic materials such as PVC at high temperature. At the same time, the white flexible surface layer 13 uses silica gel as the surface layer, the flexible surface is smooth, the plane reflectivity is high, and the imaging effect is good; no wrinkles and other abnormalities affecting the normal use performance occur during long-term use, and no folds occur after 100,000 times of winding and unwinding. Under abnormal conditions, children directly grab the projection screen 10 with their hands, almost no folds are generated, and slight folds can be quickly recovered. At the same time, the low surface tension characteristics of the silica gel material itself, the high anti-pollution characteristics, and the silica gel material are not easy to be stained with dust and other dirt, and the surface cleanliness of the projection screen 10 can be maintained for a long time.

[0064] In some embodiments, the thickness of the white flexible surface layer 13 is less than or equal to 0.50 mm (such as 0.10 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, etc.). Specifically, if the thickness of the white flexible surface layer 13 is too small, the white flexible surface layer 13 is easily damaged, thereby shortening the service life of the projection screen 10, and the white flexible surface layer 13 that is too thin may not be able to effectively reflect the projection light. If the thickness of the white flexible surface layer 13 is too large, on the one hand, the cost of the material is increased, and on the other hand, the weight of the entire projection screen 10 and the volume of the projection screen 10 after being wound are also increased. Therefore, the appropriate thickness of the white flexible surface layer 13 is beneficial to provide sufficient protection to the projection screen 10, so that the projection screen 10 is more durable, and at the same time, the white flexible surface layer 13 can effectively reflect light.

[0065] In some embodiments, the overall thickness of the projection screen 10 is less than or equal to 0.55 mm (such as 0.4 mm, 0.45 mm, 0.5 mm, 0.55 mm, etc.). In this way, after the projection screen 10 is wound, the space can be effectively saved, which is beneficial to the application of the projection screen 10 in the vehicle-mounted projection system.

[0066] In summary, through the comprehensive arrangement of the black base cloth layer 11, the black flexible primer layer 12, and the white flexible surface layer 13 in the projection screen 10, the projection screen 10 can meet the harsh use environment required by the vehicle-mounted screen.

[0067] FIG. 3 is a flow chart of a method for preparing the projection screen according to the first embodiment of the present application. As shown in FIG. 3, the method for preparing the projection screen includes the following steps S301 to S304. According to different requirements, the order of some steps or sub-steps of the method for preparing the projection screen can be changed, some steps or sub-steps can be omitted or combined. The method for preparing the projection screen can be used to prepare the projection screen 10 shown in FIG. 1.

[0068] Step S301: coating a non-cured white flexible surface layer on a carrier film.

[0069] In some embodiments, the material of the white flexible surface layer is white silica gel, but is not limited thereto.

[0070] In some embodiments, the white flexible surface layer can be formed by coating multiple times on the carrier film. For example, the white flexible surface layer can be formed by coating twice on the carrier film. That is, the white flexible surface layer can be obtained by coating a layer of white silica gel on the carrier film first, without curing, and then coating a layer of white silica gel on the non-cured white silica gel layer. Among them, forming the white flexible surface layer by multiple coating is conducive to ensuring the flatness of the white flexible surface layer. In addition, if the thickness of the white flexible surface layer is relatively thick, multiple coating can better prevent air bubbles from appearing in the coating layer, thereby affecting the optical effect.

[0071] Step S302: coating a non-cured black flexible primer layer on the non-cured white flexible surface layer.

[0072] In some embodiments, the material of the black flexible primer layer is black silica gel, but is not limited thereto. The black flexible primer layer can be obtained by roll coating a layer of black silica gel primer on the white flexible surface layer.

[0073] Step S303: bonding the side of the non-cured black flexible primer layer away from the non-cured white flexible surface layer and the black base cloth layer together in a cold-pressing manner.

[0074] In some embodiments, the black base cloth layer in step S303 is the black base cloth layer 11 shown in FIG. 2. The black base cloth layer 11 is a base cloth treated with stiffening agent.

[0075] In other embodiments, step S303 can include providing a base cloth including a loop structure formed by weaving ground yarn 11a and a weft structure formed by weft yarn 11b, and then treating the base cloth with stiffening agent so that the stiffening agent infiltrates the gap between the ground yarn 11a and the weft yarn 11b, thereby obtaining the black base cloth layer 11.

[0076] Step S304: curing the stack of the black base cloth layer, the non-cured black flexible primer layer and the non-cured white flexible surface layer at high temperature to obtain the projection screen.

[0077] In some embodiments, the step S304 comprises placing the stack of the black base cloth layer, the un-cured black flexible bottom coating layer and the un-cured white flexible surface layer into a high-temperature furnace for curing treatment.

[0078] In some embodiments, the temperature for the high-temperature curing treatment in the step S304 is 80-100°C (e.g. 80-90°C, 90-95°C, 95-100°C, etc.), so as to ensure that each film layer in the stack can be completely cured and has better mechanical strength and durability.

[0079] In the above preparation method, the white flexible surface layer is coated on the carrier film, wherein the carrier film has high surface flatness, and the contact surface between the white flexible surface layer and the carrier film is the appearance surface of the projection screen, thus effectively improving the flatness of the appearance surface of the projection screen.

[0080] In addition, the black flexible bottom coating layer is directly formed on the surface of the white flexible surface layer by coating, which can reduce the bonding layer between the black flexible bottom coating layer and the white flexible surface layer, thereby facilitating the reduction of the overall thickness of the projection screen, and effectively saving space after the projection screen is rolled up.

[0081] Further, the white flexible surface layer and the black flexible bottom coating layer are directly cold-pressed together with the black base cloth layer before curing, and then high-temperature curing treatment is performed, so that the adhesion between the white flexible surface layer, the black flexible bottom coating layer and the black base cloth layer is stronger, effectively avoiding the delamination or peeling between the layers due to different moduli, and the surface flatness of the projection screen can be further improved.

[0082] Specifically, the high-temperature curing treatment in the step S304 is equivalent to heat treatment of the black base cloth layer, which can effectively release the internal stress between the layers and reduce the problem of edge curling of the obtained projection screen. Moreover, if the edge curling phenomenon is found after rolling up, the process can be adjusted in time.

[0083] In some embodiments, the above preparation method of the projection screen further comprises cutting the edges of the obtained projection screen by punching or ultrasonic cutting. Specifically, the edges of the obtained projection screen are cut by ultrasonic cutting, which can effectively improve the side edge burrs, flaps and other phenomena, thereby effectively improving the delicate appearance of the projection screen.

[0084] FIG. 4 is a structural schematic diagram of a projection screen according to a second embodiment of the present application. As shown in FIG. 4, the projection screen 20 comprises a black base cloth layer 21, a black flexible primer layer 22 and a white flexible surface layer 23 which are sequentially stacked. The projection screen 20 is substantially the same as the projection screen 10 of the first embodiment in structure, that is, the above description of the projection screen 10 can be basically applied to the projection screen 20. The difference between the projection screen 20 and the projection screen 10 mainly lies in that the black flexible primer layer 22 of the projection screen 20 is formed with a wire grid structure 22a, the wire grid structure 22a comprises a bonding surface 221 which is bonded to the black base cloth layer 21 and projection surfaces 222 and non-projection surfaces 223 which are alternately arranged opposite to the bonding surface 221, and the white flexible surface layer 23 is arranged on the projection surfaces 222 for reflecting the projection light.

[0085] Specifically, the wire grid structure 22a is in a sawtooth shape, each sawtooth is substantially a triangular prism extending along the weft direction D1 (or the transverse direction of the projection screen 20). Each sawtooth comprises a projection surface 222 and a non-projection surface 223. The white flexible surface layer 23 is arranged on the projection surface 222 of each sawtooth as a reflecting layer for reflecting the projection light to the viewer. The non-projection surface 223 is not provided with the white flexible surface layer 23, so that the black flexible primer layer 22 serves as an absorbing layer for absorbing the ambient light incident on the non-projection surface 223, thereby improving the light resistance of the projection screen 20.

[0086] FIG. 5 is a flow chart of a preparation method of the projection screen according to the second embodiment of the present application. As shown in FIG. 5, the preparation method of the projection screen comprises the following steps S501 to S506. According to different requirements, the order of some steps or sub-steps of the preparation method of the projection screen can be changed, some steps or sub-steps can be omitted or combined. The preparation method of the projection screen can be used to prepare the projection screen 20 shown in FIG. 4.

[0087] Step S501: coating a primer material for forming a black flexible primer layer on a carrier film.

[0088] In some embodiments, the material of the black flexible primer layer is black silicone, but is not limited thereto.

[0089] Step S502: pre-solidifying the primer material.

[0090] In some embodiments, the primer material is pre-solidified by heating, but is not limited thereto.

[0091] Step S503: forming a wire grid structure on the pre-solidified primer material, the wire grid structure comprising a bonding surface and projection surfaces and non-projection surfaces which are alternately arranged opposite to the bonding surface.

[0092] In some embodiments, the wire grid structure is formed on the pre-cured base coating material by using a mold, but not limited thereto.

[0093] Step S504: fully curing the base coating material to obtain a black flexible base coating layer.

[0094] In some embodiments, the base coating material is fully cured by heating, but not limited thereto.

[0095] Step S505: forming a white flexible surface layer on the projection surface of the black flexible base coating layer by using a mask and a spraying process.

[0096] In some embodiments, the white flexible surface layer is white silica gel, but not limited thereto.

[0097] In some embodiments, the mask shields the non-projection surface and exposes the projection surface, and the white flexible surface layer is formed by the mask and the spraying process.

[0098] Step S506: adhering the side of the black flexible base coating layer away from the white flexible surface layer to the black base cloth layer to obtain a projection screen.

[0099] In some embodiments, the black base cloth layer is the black base cloth layer 11 shown in FIG. 2. The black base cloth layer 11 is a base cloth treated with stiffening agent.

[0100] In other embodiments, step S506 can include providing a base cloth including a loop structure formed by weaving ground yarn 11a and a filling structure formed by filling yarn 11b, and then treating the base cloth with stiffening agent to infiltrate the interstices of the ground yarn 11a and the filling yarn 11b, thereby obtaining the black base cloth layer 11.

[0101] In some embodiments, the method for preparing the projection screen further includes cutting the edges of the obtained projection screen by punching or ultrasonic cutting. Specifically, by cutting the edges of the obtained projection screen by ultrasonic cutting, the phenomena of side edge burrs, flaps and the like can be effectively improved, thereby effectively improving the delicate appearance of the projection screen.

[0102] FIG. 6 is a structural schematic diagram of the projection screen according to the third embodiment of the present application. As shown in FIG. 6, the projection screen 30 comprises a black base cloth layer 31, a black flexible primer layer 32 and a white flexible surface layer 33 which are sequentially stacked. The projection screen 30 is basically the same as the projection screen 10 of the first embodiment in structure, that is, the above description of the projection screen 10 can basically be applied to the projection screen 30. The difference between the projection screen 30 and the projection screen 10 mainly lies in that the white flexible surface layer 33 of the projection screen 30 is formed with a Fresnel structure 33a comprising a plurality of microstructure units 331 which are sequentially arranged outwardly based on the same center. Specifically, the black flexible primer layer 32 is the base for forming the Fresnel structure 33a, and the Fresnel structure 33a is beneficial to improving the light resistance of the projection screen 30.

[0103] In some embodiments, the black flexible primer layer 32 is selected from black transparent silica gel with large hardness, but is not limited thereto. For example, the black flexible primer layer 32 can also be selected from gray silica gel.

[0104] In some embodiments, the transmittance of the black flexible primer layer 32 is between 25% and 90% (such as 25%-40%, 40%-55%, 55%-70%, 70%-85%, 85%-90%, etc.), but is not limited thereto.

[0105] In some embodiments, the white flexible surface layer 33 is selected from transparent silica gel material, but is not limited thereto.

[0106] FIG. 7 is a flow chart of the preparation method of the projection screen according to the third embodiment of the present application. As shown in FIG. 7, the preparation method of the projection screen comprises the following steps S701 to S707. According to different requirements, the order of some steps or sub-steps of the preparation method of the projection screen can be changed, and some steps or sub-steps can be omitted or combined. The preparation method of the projection screen can be used to prepare the projection screen 30 shown in FIG. 6.

[0107] Step S701: coating a primer material for forming a black flexible primer layer on a carrier film.

[0108] In some embodiments, the primer material is black transparent silica gel or gray silica gel with large hardness, but is not limited thereto.

[0109] In some embodiments, the transmittance of the primer material is between 25% and 90% (such as 25%-40%, 40%-55%, 55%-70%, 70%-85%, 85%-90%, etc.).

[0110] Step S702: completely curing the primer material to obtain the black flexible primer layer.

[0111] In some embodiments, the base coating material is fully cured by heating, but is not limited thereto.

[0112] Step S703: coating a surface material for forming a white flexible surface layer on the black flexible base coating layer.

[0113] In some embodiments, the surface material is transparent silica gel material, but is not limited thereto.

[0114] Step S704: semi-curing the surface material.

[0115] In some embodiments, the surface material is semi-cured by heating, but is not limited thereto.

[0116] Step S705: forming a Fresnel structure on the semi-cured surface material, the Fresnel structure comprising a plurality of microstructure units arranged outwardly based on the same center.

[0117] In some embodiments, the Fresnel structure is formed on the semi-cured surface material by using a mold of the Fresnel microstructure.

[0118] Step S706: fully curing the surface material to obtain a white flexible surface layer.

[0119] In some embodiments, the surface material is fully cured by heating, but is not limited thereto.

[0120] Step S707: adhering the side of the black flexible base coating layer away from the white flexible surface layer to the black base cloth layer to obtain a projection screen.

[0121] In some embodiments, the black base cloth layer is the black base cloth layer 11 shown in FIG. 2. The black base cloth layer 11 is a base cloth treated with stiffening agent.

[0122] In other embodiments, step S506 can comprise providing a base cloth comprising a loop structure formed by weaving ground yarn 11a and a filling structure formed by filling yarn 11b, and then treating the base cloth with stiffening agent so that the stiffening agent infiltrates the gap between the ground yarn 11a and the filling yarn 11b, thereby obtaining the black base cloth layer 11.

[0123] In some embodiments, the method for preparing the projection screen described above further comprises cutting the edges of the obtained projection screen by punching or ultrasonic cutting. Specifically, by cutting the edges of the obtained projection screen by ultrasonic cutting, the phenomena of side edge burrs, burrs, etc. can be effectively improved, thereby effectively improving the delicate appearance of the projection screen.

[0124] In summary, the projection screen of the embodiment of the present application can effectively improve the anti-vibration performance of the projection screen, increase the effective display area of the projection screen, effectively reduce the thickness of the projection screen, and thus meet the high reliability (high temperature 105 DEG C, low temperature-40 DEG C, double 85 high temperature and high humidity) and long durability (10 years) requirements of the projection screen used on the car, and can be normally used in the case of slight vibration during driving, and can realize high brightness and high contrast display effect, and can effectively reduce the size of the matching structure.

[0125] More specifically, the projection screen of the embodiment of the present application has the following advantages:

[0126] First, it can be used in a wide temperature range on the vehicle: it can be used in the range of-40 DEG C to 105 DEG C, and can still maintain its flexibility in the environment of-40 DEG C, ensuring that its basic performance remains unchanged. No abnormalities occur under long-term high temperature and high temperature and high humidity.

[0127] Second, the screen has good anti-vibration performance and fast vibration diffusion, and can meet the normal use requirements of the vehicle in the vibration environment during driving.

[0128] Third, the overall thickness is thin, and the projection of the conventional size is rolled up, occupying a small area, which can effectively save the space in the vehicle.

[0129] Fourth, the projection effect is good, the double-layer black background structure can further reduce the light transmission of the screen, the screen gain is 1.0, the brightness of the screen is improved, the flexible surface is smooth, the plane reflectivity is high, and the imaging effect is good.

[0130] Fifth, the appearance is delicate: the surface flatness is good, no wrinkles or other abnormalities that affect its normal use performance occur during long-term use, the side edge warping is not more than, and no folds occur after 100,000 times of rolling and unrolling. Under abnormal conditions, children can directly grab the screen with their hands, and almost no folds are generated. The slight folds can be quickly recovered. In addition, when the white flexible surface layer is silicone, the surface energy of the silicone is low, and the anti-dirt effect is good.

[0131] The embodiment of the present application also provides a projection system. The projection system comprises a projection screen and a projector. The projector is used to project image light to the projection screen. The projection system can be a vehicle-mounted projection system, but is not limited thereto.

[0132] The embodiment of the present application also provides a vehicle. The vehicle comprises a vehicle body and a projection system, and the projection system is installed on the vehicle body, so that the user can enjoy the comfortable experience of large-screen viewing in the vehicle.

[0133] The above embodiments are only used to illustrate the technical solutions of the present application but not limit the present application, and although the present application is explained in detail with reference to the above preferred embodiments, it should be understood by those skilled in the art that the technical solutions of the present application can be modified or equivalent replaced without departing from the spirit and scope of the technical solutions of the present application.

Claims

1. A projection screen, characterized by The black base cloth layer includes a loop structure, a weft insertion structure and a fabric stiffening agent, the loop structure is knitted by ground yarn, the weft insertion structure is formed by weft insertion yarn inserted into the loop structure along the weft direction, and the fabric stiffening agent is filled in the gap between the ground yarn and the weft insertion yarn, the material of the ground yarn includes polyester and fiber reinforced material, and the material of the weft insertion yarn includes glass fiber.

2. The projection screen of claim 1, wherein, The mass fraction of the fabric stiffening agent in the black base cloth layer is 3%-4%.

3. The projection screen of claim 1, wherein, The material of the fabric stiffening agent is selected from at least one of polyvinyl acetate, polyacrylate and polyurethane fabric stiffening agent; And / or, the material of the black flexible primer layer is selected from at least one of black silica gel, thermoplastic polyurethane elastomer, thermoplastic elastomer, thermoplastic polyolefin elastomer and thermoplastic polyester elastomer; And / or, the material of the white flexible surface layer is selected from at least one of white silica gel, thermoplastic polyurethane elastomer, thermoplastic elastomer, thermoplastic polyolefin elastomer and thermoplastic polyester elastomer.

4. The projection screen of claim 1, wherein, The thickness of the black base cloth layer is 0.35mm-0.40mm; And / or, the thickness of the black flexible primer layer is less than or equal to 0.10mm; And / or, the thickness of the white flexible surface layer is less than or equal to 0.50mm; And / or, the overall thickness of the projection screen is less than or equal to 0.55mm.

5. The projection screen of any one of claims 1-4, wherein, The black flexible primer layer forms a wire grid structure, the wire grid structure includes a bonding surface bonded with the black base cloth layer and a projection surface and a non-projection surface alternately arranged opposite to the bonding surface, and the white flexible surface layer is arranged on the projection surface for reflecting projection light; Or, the white flexible surface layer forms a Fresnel structure, the Fresnel structure includes a plurality of microstructure units arranged outward in sequence based on the same center.

6. A method of manufacturing a projection screen, characterized by, Including: Coating an un-cured white flexible surface layer on a carrier film; Coating an un-cured black flexible primer layer on the un-cured white flexible surface layer; Cold-pressing the side of the un-cured black flexible primer layer away from the un-cured white flexible surface layer with a black base cloth layer, the black base cloth layer includes a loop structure, a weft insertion structure and a fabric stiffening agent, the loop structure is knitted by ground yarn, the weft insertion structure is formed by weft insertion yarn inserted into the loop structure along the weft direction, and the fabric stiffening agent is filled in the gap between the ground yarn and the weft insertion yarn, the material of the ground yarn includes polyester and fiber reinforced material, and the material of the weft insertion yarn includes glass fiber; and High-temperature curing the stack of the black base cloth layer, the un-cured black flexible primer layer and the un-cured white flexible surface layer to obtain a projection screen.

7. A method of making a projection screen, characterized by Including: coating a base coating material for forming a black flexible base coating layer on a carrier film; pre-curing the base coating material; forming a wire grid structure on the pre-cured base coating material, the wire grid structure comprising a sticking surface and projection surfaces and non-projection surfaces arranged alternately opposite to the sticking surface; fully curing the base coating material to obtain the black flexible base coating layer; forming a white flexible surface layer on the projection surfaces of the black flexible base coating layer by using a mask and spraying process; and attaching a black base cloth layer to a side of the black flexible base coating layer away from the white flexible surface layer to obtain a projection screen; the black base cloth layer comprising a loop structure, a weft filling structure and a fabric stiffener, the loop structure being knitted by ground yarns, the weft filling structure being formed by weft yarns inserted into the loop structure along the weft direction, the fabric stiffener being filled in the interspace of the ground yarns and the weft yarns, the material of the ground yarns comprising polyester and fiber reinforced material, the material of the weft yarns comprising glass fiber.

8. A method of manufacturing a projection screen, characterized by, comprising: coating a base coating material for forming a black flexible base coating layer on a carrier film; fully curing the base coating material to obtain the black flexible base coating layer; coating a surface material for forming a white flexible surface layer on the black flexible base coating layer; semi-curing the surface material; forming a Fresnel structure on the semi-cured surface material, the Fresnel structure comprising a plurality of microstructure units arranged outwardly based on the same center; fully curing the surface material to obtain the white flexible surface layer; and attaching a black base cloth layer to a side of the black flexible base coating layer away from the white flexible surface layer to obtain a projection screen; the black base cloth layer comprising a loop structure, a weft filling structure and a fabric stiffener, the loop structure being knitted by ground yarns, the weft filling structure being formed by weft yarns inserted into the loop structure along the weft direction, the fabric stiffener being filled in the interspace of the ground yarns and the weft yarns, the material of the ground yarns comprising polyester and fiber reinforced material, the material of the weft yarns comprising glass fiber.

9. The method for preparing a projection screen as described in any one of claims 6 to 8, characterized in that, further comprising: cutting the edges of the obtained projection screen by punching or ultrasonic cutting.

10. A projection system, characterized by comprising: the projection screen according to any one of claims 1 to 5; and a projector for projecting image light to the projection screen.

11. A vehicle characterized by comprising: comprising: a vehicle body; and the projection system according to claim 10, the projection system being installed on the vehicle body.

Images