Modular Curved Projection Screen Seamless Assembly
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Solution Overview
Problem
Existing large-scale projection screens are not portable, expensive, fragile, and suffer from acoustical reflections and seam issues, making them unsuitable for smaller scales and modular applications.
Innovation Solution
A modular projection screen composed of multiple curved outer and inner shell subsections with compressible material, where the inner subsections extend beyond the edges of the outer subsections and are compressed to form a seamless viewing surface, using interlocking protrusions and connectors to create a smooth seam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If formed and painted perforated aluminum panels are used to construct large scale concave projection screens, then the screen structure is rigid and stable, but the screen becomes non-portable, expensive, and fragile
Solution Approach 1:
The screen is divided into multiple modular panels that can be assembled together to form large concave structures. Each panel is a self-contained unit with standardized connection interfaces, allowing the overall structure to be disassembled and transported in sections while maintaining structural integrity when assembled.
Solution Approach 2:
The modular panels are designed to nest within each other during storage and transport, with smaller panels fitting into spaces between larger panels. This nesting arrangement significantly reduces the volume required for storage and transportation while maintaining the structural stability of the individual panels.
2Adaptability or versatility
If fabric envelope covering is used to create mobile screen surfaces, then the screen becomes portable, but seams and pillowing appear that degrade image quality
Solution Approach 1:
Each modular panel incorporates a thin fabric envelope that conforms to the curved surface of the panel's internal support structure. The fabric is tensioned uniformly across the panel surface during assembly, eliminating wrinkles and pillowing while maintaining the flexible, portable nature of the overall screen structure.
Solution Approach 2:
By dividing the screen into multiple modular panels with tight, precision-machined mating surfaces, the design eliminates the need for large continuous fabric surfaces. The seams between panels are minimized and precisely aligned, reducing visible stitching and maintaining surface smoothness across the entire display area.
3Stability of the object's composition
If shaped FRG board or molded fiberglass is used to create smaller screen surfaces, then the screen structure is rigid, but the screens become non-mobile and exhibit acoustical reflections
Solution Approach 1:
Each modular panel combines a rigid internal support structure (made from lightweight aluminum or composite materials) with a tensioned fabric envelope. This composite construction provides the rigidity needed for structural stability while keeping the overall weight low enough for mobility. The fabric layer also provides acoustic absorption to reduce reflections.
Solution Approach 2:
The fabric envelope material is selected to be acoustically transparent or porous, allowing sound waves to pass through rather than reflect off the screen surface. This eliminates the acoustical reflection problems associated with solid FRG board and fiberglass while maintaining the structural rigidity provided by the internal support framework.
4Stability of the object's composition
If modular spherical screen assembly with rigid modules is used, then the screen structure is stable, but color matching filler is required between seams which eliminates portability
Solution Approach 1:
The fabric envelope extends slightly beyond the rigid modular framework and is tensioned to create overlapping edges that meet seamlessly at the joints. This flexible fabric approach eliminates the need for rigid color-matching filler materials, as the fabric itself provides a continuous, uniform surface that conceals the joints between modular sections while maintaining portability.
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
The modular design provides a portable, cost-effective, and acoustically transparent seamless viewing surface, suitable for various sizes and shapes, including concave and spherical configurations, without the issues of seams or acoustical reflections.
Implementation Method 1
connectors coupled to the curved outer shell subsections to couple the outer shell subsections to each other causing the compressible material of adjacent inner subsections to compress, forming a seamless viewing screen
Data Source
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Figure 5
AI summary
A modular curved projection screen includes an outer structural component formed of multiple compound curved interlocking sections. Multiple inner compound curved screen components are each supported by a corresponding compound curved interlocking section and extend beyond edges of the interlocking sections. Responsive to interlocking the multiple compound curved interlocking sections, edges of adjacent screen components are compressed against each other to form a smooth concave projection viewing area supported by the outer structural component.