Curved Screen Microstructure Array for Contrast and Brightness
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Solution Overview
Problem
Curved screens face challenges in improving contrast and brightness uniformity, particularly in distinguishing incident light from ambient stray light and ensuring even light distribution across the viewing field, while also being easy to install and cost-effective.
Innovation Solution
A curved screen design featuring a black light-absorbing layer, a microstructure array layer with V-shaped recesses, and a light diffusion layer, where the microstructure array and microlens array are rotationally symmetrical and strategically arranged to optimize light reflection and scattering, with the light diffusion layer optionally composed of scattering material on the V-shaped recesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a curved screen is used to improve viewing experience and reduce edge loss, then brightness uniformity and viewing field are improved, but it becomes more difficult to distinguish incident light from ambient stray light, reducing contrast
Solution Approach 1:
The patent applies local quality by making different parts of the screen have different microstructure orientations. Each local region's microstructures are angled to reflect incident light from the projector while preventing ambient light from reaching the viewer's eye, thus locally optimizing both brightness uniformity and contrast by filtering stray light directionally
Solution Approach 2:
The patent uses asymmetry in the microstructure design where the left and right sides of the screen have mirror-symmetric but asymmetric-to-each-other orientations. This asymmetric configuration enables the screen to differentiate between incident light coming from the projector and ambient light from other directions, improving contrast while maintaining brightness uniformity across the curved surface
2Object-affected harmful factors
If microstructure angles are optimized to improve contrast by filtering stray light, then contrast is improved, but the complexity of arranging microstructures increases
Solution Approach 1:
The patent segments the screen into multiple zones with different microstructure orientations. By dividing the screen surface into distinct segments (left side, right side, center), each with simplified orientation rules, the overall complex problem of stray light rejection across the entire curved screen is broken down into manageable local segments that can be independently optimized and manufactured
Solution Approach 2:
The patent employs asymmetric microstructure orientations where the left and right sides of the screen have mirror-symmetric configurations. This asymmetric design provides an efficient and relatively simple arrangement rule that achieves effective stray light rejection without requiring complex random or irregular patterns, thus balancing contrast improvement with manufacturing simplicity
3Illumination intensity
If a light diffusion layer is added to spread light and improve viewing field, then brightness uniformity is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the light diffusion function with the existing microstructure array layer by incorporating diffusion materials directly into the microstructure design. This integration combines the light reflection and diffusion functions into a single layer, achieving brightness uniformity improvement without adding separate diffusion layers, thus avoiding increased device complexity and manufacturing cost
Solution Approach 2:
The patent makes the microstructure array layer multi-functional by enabling it to simultaneously perform light reflection, diffusion, and stray light filtering functions. By giving the microstructure layer universal functionality, the patent eliminates the need for additional specialized layers, thereby maintaining device simplicity while achieving improved brightness uniformity and viewing field
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances contrast and brightness uniformity by effectively separating incident and ambient light, increasing the viewing field, and simplifying installation, while improving light utilization and reducing costs.
Implementation Method 1
a black light-absorbing layer, a microstructure array layer
Implementation Method 2
arranging angles of the total reflection diffusion layer, not only incident light of the projector and ambient stray light are effectively distinguished from each other
Implementation Method 3
light is reflected into the viewer's viewing field at a certain scattering angle, the viewing field is increased
Data Source
AI summary
A curved screen comprises the following layers sequentially arranged from inside to outside: a black light-absorbing layer, a microstructure array layer, and a transparent matrix layer. The microstructure array layer consists of a plurality of microstructure units. The microstructure unit is a V-shaped recess consisting of two intersecting inclined surfaces. The microstructure array layer is rotationally symmetrical with respect to a center line of the curved screen. Angles of the V-shaped recesses in respective longitudinal cross sections of the curved screen are uniquely determined according to incident angles of light rays from a projector. Also disclosed are a method of arranging microstructures in the curved screen and a projection system comprising the curved screen. The curved screen has a higher contrast, improved brightness uniformity and an enlarged field of view.