Front projection screens including reflecting and refractive layers of differing spatial frequencies
First Claim
Patent Images
1. A projection screen comprising:
- a substrate;
a reflective layer on the substrate, the reflective layer comprising reflective microstructures of about 0.5 μ
m to about 500 μ
m in size and arranged in a first pattern to reflect light at a first spatial frequency; and
a refractive layer on the substrate, the refractive layer comprising refractive microstructures of about 0.5 μ
m to about 500 μ
m in size and arranged in a second pattern that is different from the first pattern to refract light at a second spatial frequency that is different than the first spatial frequency;
wherein the projection screen has a front and a back and wherein the reflective layer and the refractive layer are arranged on the substrate such that light that is projected to the front of the projection screen passes through and is refracted by the refractive layer to impinge on the reflective layer and is reflected from the reflective layer back through the refractive layer to emerge from the front of the projection screen; and
wherein the projection screen has a vertical axis and a horizontal axis and wherein the reflective layer and/or the refractive layer are configured to produce a vertical half angle of the light that emerges from the front of the projection screen that is less than a horizontal half angle of the light that emerges from the front of the projection screen.
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Abstract
Projection screens include a substrate, a reflective layer on the substrate and a refractive layer on the substrate. The reflective layer includes reflective microstructures of about 5 μm to about 500 μm in size, and arranged in a first pattern to reflect light at a first spatial frequency. The refractive layer includes refractive microstructures of about 5 μm to about 500 μm in size, and arranged in a second pattern that is different from the first pattern, to refract light at a second spatial frequency that is different than the first spatial frequency. Related fabrication methods also are described.
48 Citations
26 Claims
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1. A projection screen comprising:
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a substrate; a reflective layer on the substrate, the reflective layer comprising reflective microstructures of about 0.5 μ
m to about 500 μ
m in size and arranged in a first pattern to reflect light at a first spatial frequency; anda refractive layer on the substrate, the refractive layer comprising refractive microstructures of about 0.5 μ
m to about 500 μ
m in size and arranged in a second pattern that is different from the first pattern to refract light at a second spatial frequency that is different than the first spatial frequency;wherein the projection screen has a front and a back and wherein the reflective layer and the refractive layer are arranged on the substrate such that light that is projected to the front of the projection screen passes through and is refracted by the refractive layer to impinge on the reflective layer and is reflected from the reflective layer back through the refractive layer to emerge from the front of the projection screen; and wherein the projection screen has a vertical axis and a horizontal axis and wherein the reflective layer and/or the refractive layer are configured to produce a vertical half angle of the light that emerges from the front of the projection screen that is less than a horizontal half angle of the light that emerges from the front of the projection screen. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A projection screen comprising:
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a substrate; a reflective layer on the substrate, the reflective layer comprising reflective microstructures of about 0.5 μ
m to about 500 μ
m in size and arranged in a first pattern to reflect light at a first spatial frequency; anda refractive layer on the substrate, the refractive layer comprising refractive microstructures of about 0.5 μ
m to about 500 μ
m in size and arranged in a second pattern that is different from the first pattern to refract light at a second spatial frequency that is different than the first spatial frequency;wherein the projection screen has a front and a back and wherein the reflective layer and the refractive layer are arranged on the substrate such that light that is projected to the front of the projection screen passes through and is refracted by the refractive layer to impinge on the reflective layer and is reflected from the reflective layer back through the refractive layer to emerge from the front of the projection screen; and wherein the projection screen has a vertical axis and a horizontal axis and wherein the first pattern comprises a plurality of grooves that extend along the vertical axis and wherein the refractive microstructures comprise a plurality of anamorphic microlenses having a vertical half angle that is less than a horizontal half angle thereof. - View Dependent Claims (10, 11, 12, 13, 14)
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15. A projection screen comprising:
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a substrate; a reflective layer on the substrate, the reflective layer comprising reflective microstructures of about 0.5 μ
m to about 500 μ
m in size and arranged in a first pattern to reflect light at a first spatial frequency; anda refractive layer on the substrate, the refractive layer comprising refractive microstructures of about 0.5 μ
m to about 500 μ
m in size and arranged in a second pattern that is different from the first pattern to refract light at a second spatial frequency that is different than the first spatial frequency;wherein the projection screen has a front and a back and wherein the reflective layer and the refractive layer are arranged on the substrate such that light that is projected to the front of the projection screen passes through and is refracted by the refractive layer to impinge on the reflective layer and is reflected from the reflective layer back through the refractive layer to emerge from the front of the projection screen; and wherein the projection screen has a vertical axis and a horizontal axis and wherein the first pattern comprises a plurality of anamorphic reflectors having a vertical half angle that is less than a horizontal half angle thereof and wherein the refractive microstructures comprise a plurality of anamorphic microlenses having a vertical half angle that is less than a horizontal half angle thereof. - View Dependent Claims (16, 17, 18, 19, 20)
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21. A projection screen comprising:
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a substrate including a reflective metal face having a textured surface to provide reflective microstructures of about 0.5 μ
m to about 500 μ
m in size and arranged in a first pattern to reflect light at a first spatial frequency; andan array of refractive microstructures of about 0.5 μ
m to about 500 μ
m in size on the textured surface and arranged in a second pattern that is different from the first pattern to refract light at a second spatial frequency that is different than the first spatial frequency;wherein the projection screen has a vertical axis and a horizontal axis and wherein the first pattern comprises a plurality of grooves that extend along the vertical axis and wherein the refractive microstructures comprise a plurality of anamorphic microlenses having a vertical half angle that is less than a horizontal half angle thereof. - View Dependent Claims (22, 23)
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24. A projection screen comprising:
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a transparent substrate having front and back faces; a first array of refractive microstructures of about 0.5 μ
m to about 500 μ
m in size on the front face, and arranged in a first pattern to refract light at a first spatial frequency;a second array of refractive microstructures of about 0.5 μ
m to about 500 μ
m in size on the back face, and arranged in a second pattern that is different from the first pattern to refract light at a second spatial frequency that is different than the first spatial frequency; anda reflective layer that extends conformally on the second array of micro structures to provide an array of reflective microstructures of about 0.5 μ
m to about 500 μ
m in size on the back face, and arranged in the second pattern to reflect light at the second spatial frequency;wherein the projection screen has a vertical axis and a horizontal axis and wherein the first and second arrays of refractive microstructures comprise respective first and second arrays of anamorphic microlenses having vertical half angles that are less than horizontal half angles thereof. - View Dependent Claims (25, 26)
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Specification