Transparent projection screen, and manufacturing method for same

A transparent projection screen and a manufacturing method. The transparent projection screen is for receiving projection light and transmitting ambient light and comprises a first substrate layer, a Fresnel structure layer, a surface diffusion layer, a nano metal plating layer, and a binding adhesive layer. The Fresnel structure layer is disposed on the first substrate layer and comprises a prism surface. The surface diffusion layer is disposed on a portion of the prism surface. The nano metal plating layer is disposed on the surface diffusion layer. The binding adhesive layer is disposed on the nano metal plating layer and fills and levels the prism surface. The projection light passes the first substrate layer and is incident on the prism surface and then reflected thereby. The ambient light passes the binding adhesive layer, the nano metal plating layer, the surface diffusion layer and the first substrate layer, and is emitted.

FIELD

The present disclosure relates to the technical field of projection screens, and in particular, to a transparent projection screen and a manufacturing method for the transparent projection screen.

BACKGROUND

A transparent projection screen can display a clear image on a transparent screen, and an observer can observe a background behind the screen through the screen, so that image information can be fused with background information to provide richer information interaction for the observer. A picture size of an existing projection screen is determined by a distance between a projection device and the projection screen. The larger the distance is, the larger the projection screen will be. An ultra-short-throw projection screen can perform projection at a short distance, which greatly saves space and increases occasions in which projection can be applied. Therefore, how to combine ultra-short-throw projection with transparent display technology to manufacture a transparent projection screen applicable to ultra-short-throw, and how to combine the advantages of the two to bring a better transparent display effect have been an unremitting pursuit in the technical field of projection display.

SUMMARY

An objective of the present disclosure is to provide a transparent projection screen and a manufacturing method for same.

Embodiments of the present disclosure achieve the above objective through the following technical solutions.

In a first aspect, the present disclosure provides a transparent projection screen configured to receive projection light and transmit ambient light, including a first substrate layer, a Fresnel structure layer, a surface diffusion layer, a nano metal plating layer, a binding adhesive layer. The Fresnel structure layer is provided at the first substrate layer, and the Fresnel structure layer includes a prism surface. The surface diffusion layer is provided at at least a portion of the prism surface. The nano metal plating layer is provided at the surface diffusion layer. The binding adhesive layer is provided at the nano metal plating layer. The binding adhesive layer fills and levels the prism surface; a refractive index of the Fresnel structure layer is the same as a refractive index of the binding adhesive layer; the projection light passes through the first substrate layer and is incident on the prism surface and then reflected by the prism surface; and the ambient light sequentially passes through the binding adhesive layer, the nano metal plating layer, the surface diffusion layer, and the first substrate layer, and then is outputted.

In a second aspect, the present disclosure provides a manufacturing method for a transparent projection screen, including: providing a first substrate layer; providing a Fresnel structure layer at the first substrate layer, the Fresnel structure layer including a prism surface; providing a surface diffusion layer at at least a portion of the prism surface; providing a nano metal plating layer at the surface diffusion layer; and providing a binding adhesive layer at the nano metal plating layer, the binding adhesive layer filling and leveling the prism surface, and a refractive index of the Fresnel structure layer being the same as a refractive index of the binding adhesive layer.

Compared with the related art, in the transparent projection screen and the manufacturing method for same according to the present disclosure, the surface diffusion layer and the nano metal plating layer are sequentially provided at the prism surface of the Fresnel structure layer, so that the prism surface has great light scattering capability, which can improve a viewing angle of the screen and ensure clarity of a projected image while realizing ultra-short-throw projection. In addition, the binding adhesive layer having a same refractive index as the Fresnel structure layer fills and levels the prism surface, which can reduce an influence on the propagation direction and phase of the ambient light therethrough, so that most of the ambient light can reach an observer's eye through the screen, thereby improving the transparency of the transparent projection screen.

DETAILED DESCRIPTION

To facilitate illustrating embodiments of the present disclosure, a detailed description of the embodiments of the present disclosure will be given below with reference to the relevant accompanying drawings. Preferred embodiments of the present disclosure are given in the drawings. However, the present disclosure may be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided herein to make the contents disclosed in the present disclosure more understandable.

Unless defined otherwise, all technical and scientific terms used herein have the same meanings as would generally understood by those skilled in the technical field of the present disclosure. The terms used herein in the embodiments of the present disclosure are for the purpose of describing specific embodiments only, and are not intended to limit the present disclosure.

In the existing transparent projection screen, a picture size is determined by a distance between the projection device and the projection screen, and a projected picture can be enlarged only by increasing the distance, which leads to a limitation on the scenarios in which the transparent projection screen can be applied. The ultra-short-throw projection screen can perform projection at a short distance, thereby greatly reducing a distance between the projection device and the projection screen and thus increasing the occasions in which projection can be applied. Therefore, based on the ultra-short-throw projection in combination with the transparent display technology, an embodiment of the present disclosure provides a transparent projection screen applicable to ultra-short-throw, which can achieve clear image projection while maintaining a transparent state of the screen, has a certain gain and field of view, and can be applied to home display screens, space design, exhibition display, window display and other aspects.

Referring toFIG.1andFIG.2, an embodiment of the present disclosure provides a transparent display screen100configured to receive projection light200and transmit ambient light300. The transparent display screen100includes a first substrate layer51, a Fresnel structure layer10, a surface diffusion layer20, a nano metal plating layer30, and a binding adhesive layer40.

The Fresnel structure layer10is disposed at the first substrate layer51, and the Fresnel structure layer10includes a prism surface11. The surface diffusion layer20is disposed at at least a portion of the prism surface11. The nano metal plating layer30is disposed at the surface diffusion layer20. The binding adhesive layer40is disposed at the nano metal plating layer30, and fills and levels the prism surface11, and the binding adhesive layer40has a same refractive index as the nano metal plating layer30. The projection light200passes through the first substrate layer51and is incident on the prism surface11and then reflected by the prism surface11. The ambient light300sequentially passes through the binding adhesive layer40, the nano metal plating layer30, the surface diffusion layer40, and the first substrate layer51, and is outputted.

The projection light200may be generated by a projector400, the surface diffusion layer20can scatter the projection light200, and the nano metal plating layer30can reflect the projection light200and transmit the ambient light300at the same time, so that the prism surface11has a great light scattering capability. As a result, a projected image with a certain gain and field of view can still be achieved to ensure clarity of the projected image even if the projector400casts the projection light200over a short distance. At the same time, the binding adhesive layer40, which has a same refractive index as the Fresnel structure layer10, fills and levels the prism surface11, and a flat surface is formed at a side of the transparent projection screen100facing away from the first substrate layer51, thereby reducing an influence on the propagation direction and phase of the ambient light300when the ambient light passes through the screen, so that most of the ambient light300can reach the observer's eyes through the screen, bringing a better transparent display effect.

It is to be noted that a metal plating layer with a normal thickness is opaque, but when the metal layer is nanometer thick, the metal layer can reflect some of the light and absorb some of the light, and the rest of the light can pass through the metal layer to form transmitted light.

In an embodiment of the present disclosure, the Fresnel structure layer10includes a plurality of microprism units13. A plurality of microprism units13with equal distances from the center form an arc, and a plurality of microprism units13with unequal distances from the center form a plurality of concentric arcs (seeFIG.6for details). Each microprism unit13includes a first prism surface111, a second prism surface112, and a side surface12. A longitudinal section of the microprism unit13, that is, a section perpendicular to a wall or a mounting plane, may be a right triangle. The first prism surface111corresponds to a hypotenuse of the right triangle, and the second prism surface112and the side surface12correspond to two right-angle sides of the right triangle, respectively. During usage, the side surface12is roughly perpendicular to a ground plane, and the second prism surface112is located at a lower side of the side surface12and is parallel to the ground plane. An angle formed between the first prism surface111and the side surface12is an acute angle.

In some embodiments, the prism surface11includes a first prism surface111and a second prism surface112, the surface diffusion layer20and the nano metal plating layer30are sequentially disposed at the first prism surface111, part of the projection light100passes through the side surface12and is incident on the first prism surface111and then reflected by the first prism surface111, part of the projection light100passes through the second prism surface112and is incident on the prism surface11and then reflected by the prism surface11, and the ambient light300sequentially passes through the first prism surface111and the side surface12and is then outputted.

It is to be noted that an inclination angle of the first prism surface111, that is, the angle formed between the first prism surface111and the side surface12, may be calculated according to an orientation relationship between the projector400and the transparent projection screen100and a region where a viewer is located, so as to ensure that the viewer can obtain the best viewing experience. A specific calculation process thereof may be obtained with reference to the existing projection display technology, which is not specifically described/limited in this embodiment.

In an embodiment of the present disclosure, a refractive index of the Fresnel structure layer10is the same as that of the binding adhesive layer40, and the Fresnel structure layer10and the binding adhesive layer40may be made by transparent organic materials with a same refractive index, such as Polyethylene terephthalate (PET) and polymethyl methacrylate (PMMA).

In an embodiment of the present disclosure, the first substrate layer51is disposed at the side surface12, and visible light transmittance of the first substrate layer51is greater than 90%. In an example, the first substrate layer51may be made by a transparent organic material such as PET or PMMA. The first substrate layer51is used as a substrate structure, which can ensure a transparent display effect of the transparent projection screen100due to its higher visible light transmittance.

In some embodiments, the longitudinal section of the microprism unit13may be roughly a right trapezoid (seeFIG.3for details), the side surface12corresponds to a right-angle side of the right trapezoid, the first prism surface111corresponds to a hypotenuse of the right trapezoid, and the second prism surface112corresponds to a lower base of the right trapezoid. In this embodiment, there is no need to provide an additional substrate structure on the Fresnel structure layer10, and those skilled in the art can selectively provide the first substrate layer51on the Fresnel structure layer10as required.

In this embodiment, the transparent projection screen100further includes a second substrate layer52. The second substrate layer52is disposed at a side of the binding adhesive layer40facing away from the Fresnel structure layer10, and visible light transmittance of the second substrate layer52is greater than 90%. In an example, the second substrate layer52may be made by a transparent organic material such as PET or PMMA. The second substrate layer52is used as a substrate structure, which can ensure a transparent display effect of the transparent projection screen100due to its higher visible light transmittance.

It is to be noted that a longitudinal section of the binding adhesive layer40corresponding to part of each microprism unit13may be a regular graphic such as a right triangle or a right trapezoid. When a cross section of the binding adhesive layer40is a right trapezoid, there is no need to provide an additional substrate structure on the binding adhesive layer40, and those skilled in the art can selectively provide the second substrate layer52on the binding adhesive layer40as required.

In an embodiment, the transparent projection screen100further includes a first antireflection layer61. The first antireflection layer61is disposed at a side of the first substrate layer51facing away from the prism surface11, visible light reflectance of the first antireflection layer61is smaller than 0.6%, and visible light transmittance of the first antireflection layer61is greater than 98%. The first antireflection layer61is disposed at an outer side of the first substrate layer51, which can reduce reflected light, improve the transparency of the transparent projection screen100, and improve the clarity of a projected picture.

In an embodiment, the transparent projection screen100further includes a second antireflection layer62. The second antireflection layer62is bonded to a side of the second substrate layer52facing away from the binding adhesive surface40, visible light reflectance of the second antireflection layer62is smaller than 0.6%, and visible light transmittance of the second antireflection layer62is greater than 98%. The second antireflection layer62is disposed at an outer side of the second substrate layer52, which can reduce reflected light, improve the transparency of the transparent projection screen100, and improve the clarity of a projected picture.

In an example, the first antireflection layer61and the second antireflection layer62may be multi-layer dielectric plating films, which can bring a better antireflection effect in a wider spectrum.

Referring toFIG.4,FIG.5, and Table 1, in an embodiment, the nano metal plating layer30is a nano aluminum plating layer. As can be seen from the figures, in a certain range, as the thickness of the nano aluminum plating layer increases, the visible light reflectance by the nano aluminum plating layer increases gradually, and the transmittance to the visible light decreases gradually. Therefore, visible light reflectance and visible light transmittance of the nano aluminum plating layer can be finally controlled to meet parameter requirements by controlling the thickness of the nano aluminum plating layer.

TABLE 1Relationship between the thickness and visible light reflectanceand transmittance of the nano aluminum plating layerSerial numberABCDEAluminum layer thickness (nm)2018161412Visible light average reflectance (%)2017.5151310.5Visible light average transmittance (%)6266717680

In an embodiment, the nano aluminum plating layer has a thickness ranging from 12 nm to 20 nm, visible light reflectance of the nano aluminum plating layer ranges from 10% to 20%, and visible light transmittance of the nano aluminum plating layer ranges from 60% to 80%. The nano metal plating layer with the above configuration ensures good transparency of the screen while ensuring the clarity of transparent projection screen100, which can meet the parameter requirements of the transparent projection screen100.

In some other embodiments, the nano metal plating layer30may be made by some other metal materials such as silver metal or aluminum-silver metal compositions. The light can also be reflected and transmitted by controlling the thickness of the plating layer.

Referring toFIG.6, in an embodiment, the surface diffusion layer20is configured to form a light scattering structure at the prism surface11. The projection light200can be diffused at a wider direction range when reaching the surface diffusion layer20, so as to increase a visualization range of the projected image, that is, increase a field of view of the transparent projection screen.

Referring toFIG.7, in an embodiment, a scattering angle of the surface diffusion layer20is controlled to be within a range from 10° to 40°. If the scattering angle is too small (e.g., smaller than 10°), the field of view of the screen is too small; and if the scattering angle is too large (e.g., greater than 40°), total reflection may occur, so that part of the projection light200cannot be reflected back, thereby affecting light efficiency.

A specific calculation process of the scattering angle of the surface diffusion layer20is as follows. The refractive index of the first substrate layer51is defined as n1, and a refractive index of an air layer500is defined as n2. If the refractive index n1of the first substrate layer51ranges from 1.5 to 1.6 and the refractive index n2of the air layer500is 1, then, when the reflected light of the projection light200returns from the first substrate layer51to the air layer500, since their refractive indexes are different and the refractive index n1of the first substrate layer51is greater than the refractive index n2of the air layer500, it can be obtained, by calculation according to the refraction law n1sin θ1=n2sin θ2, that θ1is about 40° in a case of total reflection (θ2=90°).

In an embodiment, the surface diffusion layer20includes a resin film and transparent scattered particles distributed in the resin film. These transparent scattered particles can scatter the projection light to realize a scattering function of the surface diffusion layer20. The surface diffusion layer20may be cured by coating the prism surface11with a mixture of the resin film and the transparent scattered particles. Since the process of coating the surface diffusion layer20is simple and easy to operate, the manufacturing process for the transparent projection screen100is simple and manufacturing costs thereof can be reduced.

The resin film has a thickness that may range from 1 μm to 10 μm. The resin film may be made by any transparent resin such as polycarbonate or polypropylene, provided that the refractive index of the resin film is controlled to be within a range from 1.5 to 1.6. The transparent scattered particles have a particle size that may range from 1 μm to 5 μm. The transparent scattered particles may be one or more of SiO2particles and PMMA particles, which can achieve better refractive index matching.

It may be understood that the scattering angle of the surface diffusion layer20may be easily controlled by changing the particle size of the transparent scattered particles, a mixing ratio of the transparent scattered particles to the resin film, and a curing temperature, so that the scattering angle of the surface diffusion layer20can be within a range from 10° to 40°, so as to meet functional requirements of the transparent projection screen100.

In an embodiment, the refractive indexes of the Fresnel structure layer10and the binding adhesive layer40may be 1.5, so that the refractive index of the surface diffusion layer20is basically the same as that of the Fresnel structure layer10and the binding adhesive layer40, so as to reduce an influence on the propagation direction and phase of the ambient light300therethrough, thereby further improving the transparency of the transparent projection screen100.

In another embodiment, the surface diffusion layer20includes a light scattering structure having concave and convex. The light scattering structure is provided at the prism surface11and integrally formed with the Fresnel structure layer10. The light scattering structure may be directly formed at the prism surface11by physical grinding or chemical etching, so there is no need to provide the scattering structure separately, thereby reducing manufacturing costs. Moreover, the integrated structure greatly improves structural stability between the Fresnel structure layer10and the surface diffusion layer20.

In addition, the integrally formed light scattering structure is made by a same material as the Fresnel structure layer10, which can ensure that the Fresnel structure layer10, the surface diffusion layer20, and the binding adhesive layer40have a same refractive index, thereby further improving the transparency of the transparent projection screen100.

It can be understood that, by changing the concave and convex degree of the light scattering structure, such as a height of the convex or a depth of the concave, the scattering angle of the surface diffusion layer20can be controlled to be within a range from 10° to 40°, so as to meet the functional requirements of the transparent projection screen100.

Referring toFIG.1again, when the transparent projection screen100is in operation, the projection light200sequentially passes through the first antireflection layer61and the first substrate layer52, is incident on the prism surface11and reflected by the prism surface11, and then is provided to be within the viewer's field of view; and the ambient light300sequentially passes through the second antireflection layer62, the second substrate layer52, the binding adhesive layer40, the nano metal plating layer30, the surface diffusion layer20, the Fresnel structure layer10, the first substrate layer51, and the first antireflection layer61, and is then outputted. According to the embodiments of the present disclosure, an overall visible light transmittance of the transparent projection screen100may finally be greater than 50%, which ensures good transparency of the transparent projection screen100.

Referring toFIG.1andFIG.8, an embodiment of the present disclosure further provides a manufacturing method for a transparent projection screen. The manufacturing method may include the following steps.

In step S10, a first substrate layer51is provided.

In step S20, a Fresnel structure layer10is provided at the first substrate layer51, and the Fresnel structure layer10includes a prism surface11.

In some embodiments, the Fresnel structure layer10may be formed with the following method. The Fresnel structure layer10is formed on the first substrate layer51by hot pressing or UV structural adhesive transfer. A thickness of the first substrate layer51can be selected according to actual requirements. In an example, the thickness of the first substrate layer51may be within a range from 50 μm to 200 μm.

In step S30, a surface diffusion layer20is provided at at least a portion of the prism surface11.

In some embodiments, the step in which a surface diffusion layer20is provided at at least a portion of the prism surface11includes step S311and step S312.

In step S311, a mixture of a resin film and transparent scattered particles is prepared.

In step S312, at least a portion of the prism surface11is coated with the mixture by spray coating or roller coating to form the surface diffusion layer20.

In some embodiments, the step in which a surface diffusion layer20is provided at at least a portion of the prism surface11includes step S321.

In step S321, at least a portion of the prism surface11is formed with concave and convex by physical grinding or chemical etching to form the surface diffusion layer20.

In step S40, a nano metal plating layer30is provided at the surface diffusion layer20.

In some embodiments, the nano metal plating layer30may be a nano aluminum plating layer. The nano aluminum plating layer may be plated on the surface diffusion layer20by sputter coating. A thickness of the nano aluminum plating layer may be within a range from 12 nm to 20 nm. A specific value may be selected according to parameter requirements of a product.

In step S50, a binding adhesive layer40is provided at the nano metal plating layer30, and the binding adhesive layer40fills and levels the prism surface11. The binding adhesive layer40may be made by directly coating the nano metal plating layer30with binding adhesive.

In some embodiments, the manufacturing method for the transparent projection screen may further include step S60.

In step S60, a second substrate layer52is provided at a side of the binding adhesive layer40facing away from the Fresnel structure layer10. The binding adhesive layer40provides an adhesive force to bind the second substrate layer52directly to the binding adhesive layer40.

In some embodiments, the manufacturing method for the transparent projection screen may further include step S71to step S72.

In step S71, a first antireflection layer61is provided at a side of the first substrate layer51facing away from the prism surface11.

In some embodiments, the first antireflection layer61may be a multi-layer dielectric plating film. The multi-layer dielectric plating film may be plated on the first substrate layer51by sputter coating to form the first antireflection layer61.

In step S72, a second antireflection layer62is provided at a side of the second substrate layer52facing away from the binding adhesive layer40.

In some embodiments, the second antireflection layer62may be a multi-layer dielectric plating film. The multi-layer dielectric plating film may be plated on the second substrate layer52by sputter coating to form the second antireflection layer62.

The transparent projection screen100obtained with the above manufacturing method has a stable structure, and is easy to operate and has a low cost.

Based on the above, according to the transparent projection screen100and the manufacturing method for same, the surface diffusion layer20and the nano metal plating layer30are sequentially provided at the prism surface11, so that the prism surface11has great light scattering capability, which can improve a viewing angle of the screen and ensure clarity of a projected image while realizing ultra-short-throw projection. At the same time, the binding adhesive layer40having a same refractive index as the Fresnel structure layer10fills and levels the prism surface11, which can reduce an influence on the propagation direction and phase of the ambient light300therethrough, so that most of the ambient light300can reach the observer's eyes through the screen, improving the transparency of the transparent projection screen100. In addition, the transparent projection screen100has a simple structure, requires no separate power supply, and is easy to use.

The above embodiments only describe several implementations of the present disclosure, which are described specifically and in detail, and therefore cannot be construed as a limitation on the patent scope of the present disclosure. It should be noted that those of ordinary skill in the art may also make several changes and improvements without departing from the concept of the present disclosure, all of which shall fall within a protection scope of the present disclosure. Therefore, the scope of the present disclosure shall be subject to the appended claims.