The present invention is directed to a rear-projection screen which encompasses 1) a flexible light-diffusive first film having a substantially smooth first surface and an opposing substantially smooth second surface, and comprising a wax-free amorphous thermoplastic matrix having a plurality of light-diffusing particles dispersed therein and which is lens-free; and 2) an opposing flexible light-absorption second film having a first surface and an opposing second surface, and comprising a thermoplastic matrix having a plurality of light-absorbing particles dispersed therein, wherein the first and second films are adapted to be 3) bonded together in direct contact with each other and then, affixed as a laminate to one or more transparent rigid substrates or 4) affixed individually to a transparent rigid substrate.

TECHNICAL FIELD

This invention relates to a rear-projection screen and in particular a rear-projection screen having at least two layers which enhances the image-contrast of a projected image and reduces the effect of ambient light.

BACKGROUND OF THE INVENTION

Rear-projection screens are utilized for various applications, such as, for example, advertising in store windows, show rooms, exhibitions, shopping malls, lobbies, restaurants, museums and various transportation stations. In such applications, an image source located behind the screen projects image light forward along a projection axis toward the screen to form a visible image at the plane of the screen which is distributed to viewers on both the receiving or rear side of the screen and the opposing, front side of the screen. Typical screen characteristics used to describe a screen's performance include contrast, image brightness, visible light transmittance, visible light absorbance and visible light reflectance.

It is generally desirable to have a rear-projection screen where the image is visible on both the front and rear surfaces and that has high image contrast and high image brightness in daylight and at night. Unfortunately, as one screen characteristic is improved, one or more other screen characteristics often degrade. For example, image contrast can be somewhat improved by incorporating a light-absorbing materials and/or light-diffusing elements in the screen for redirecting the ambient light. Often when the reflected ambient light is reduced by this technique, image brightness on one or both surfaces is also reduced because the screen has become more opaque. As a result, there is little or no effective gain in the image quality. For this reason, certain tradeoffs are made in screen characteristics and performance in order to produce a screen that has acceptable overall performance for the particular rear-projection display application. Display applications intended to be viewable on a window from both the interior and exterior of a building are particularly challenging to manufacturers since that the relative amount of sunlight reflected from the window is much greater than the ambient light reflected inside of the building.

BRIEF SUMMARY OF THE INVENTION

The primary object of the invention is to provide a rear-projection screen having improved image contrast and very little, if any, reflection of sunlight to a viewer located outside of a building. It has been discovered that a rear-projection screen having a visible light transmittance of between 25 to 50% and visible light absorbance of between 35 to 55% would exhibit the desired image contrast.

Another object of the invention is to provide a rear-projection screen having improved image contrast and enhanced image brightness while providing a viewable image to viewers located inside and outside of a building. It has been discovered that a rear-projection screen having a visible light transmittance of between 25 to 50% and visible light absorbance of between 35 to 55% would exhibit the desired image contrast.

Still another object of the invention is to provide a rear-projection screen having improved image contrast and enhanced image brightness which is be easily and temporarily or permanently mountable onto a transparent substrate such as a store window for viewing of a projected image inside and outside of a building.

Still yet another object of the invention is to provide a rear-projection screen that is both relatively inexpensive to manufacture and very high quality, and meets all of the requirements set out above for an improved rear-projection screen.

The above objects and advantages of the invention are attained by a rear-projection screen which encompasses 1) a flexible light-diffusive first film having a substantially smooth first surface and an opposing substantially smooth second surface, and comprising a wax-free amorphous thermoplastic matrix having a plurality of light-diffusing particles dispersed therein and which is lens-free; and 2) an opposing flexible light-absorption second film having a first surface and an opposing second surface, and comprising a thermoplastic matrix having a plurality of light-absorbing particles dispersed therein, wherein the first and second films are adapted to be 3) bonded together in direct contact with each other and then, affixed as a laminate to one or more transparent rigid substrates or 4) affixed individually to a transparent rigid substrate.

DETAILED DESCRIPTION

The term “lens-free” as used herein refers to light-diffusive films which do not include the following: any repeating geometric structure, such as, for example, trough-like and post-like features, embedded within the film or on the surface of the screen, which focuses or defocuses light passing through it; Fresnel lens; lenticular lens; and any other optically transparent device which focuses or defocuses light passing through it. Rear-projection screen utilizing the aforementioned lens for light diffusion are known in the art and have been described for example, in U.S. Pat. Nos. 3,832,032; 4,003,080; 4,573,764; 4,666,248; 7,142,361; 6,204,971; 6,765,720 and RE38,245, the disclosures of which are incorporated herein by reference in their entireties. U.S. Pat. No. 3,832,032 describes a transparent projection screen comprising Fresnel lenses which faces the primary image-source. U.S. Pat. Nos. 4,003,080 and 4,666,248 describe a rear-projection screen comprising a single sheet which at its back carries a multitude of lens elements arranged in a two dimensional matrix. U.S. Patent No. discloses a rear-projection screen which uses a front surface lenticular array to distribute projected light. U.S. Pat. No. 7,142,361 describes microstructured protrusions and indentions arranged internally in a multilayered projection screen. U.S. Pat. Nos. 6,204,971; 6,765,720 and RE38,245 each describe an array of closely packed glass microspheres or beads on a film surface for use in a rear-projection screen.

As used herein, the term “thermoplastic” refers to a polymer or polymer mixture that softens when exposed to heat and returns to its original condition when cooled to room temperature. In general, thermoplastic materials include, but are not limited too, synthetic polymers such as polyolefins, polyesters, vinyl acetate copolymers, and the like. Thermoplastic materials may also include any synthetic polymer that is cross-linked by either radiation or chemical reaction during a manufacturing process operation. The term “amorphous” refers to thermoplastic polymer or copolymer with an absence of a regular three-dimensional arrangement of molecules or subunits of molecules extending over distances, which are large relative to atomic dimensions. However, regularity of structure exists on a local scale. See, “Amorphous Polymers,” inEncyclopedia of Polymer Science and Engineering,2nd Ed., pp. 789-842 (J. Wiley & Sons, Inc. 1985). This document has a Library of Congress Catalogue Card Number of 84-19713. In particular, the term “amorphous” as used with respect to the present invention refers to a material recognized by one skilled in the art of differential scanning calorimetry (DSC) as having no measurable melting point (less than 0.5 cal/g) or no heat of fusion as measured by DSC using ASTM 3417-83. The term “polymer” refers to the product of a polymerization reaction, and is inclusive of homopolymers, copolymers, terpolymers, etc. In general, the layers of a film as used herein can consist essentially of a single polymer, or can have still additional polymers together therewith, i.e., blended therewith. Particularly suitable amorphous thermoplastic polymer or copolymer for use in the present invention includes, but is not limited to, polyolefins, polyesters, and polyvinyl chlorides.

“Polyolefin” refers to homopolymers, copolymers, including e.g. bipolymers, terpolymers, etc., having a methylene linkage between monomer units which may be formed by any method known to those skilled in the art. Suitable examples of polyolefins include polyethylene, low density polyethylene, linear low density polyethylene, very low density polyethylene, ultra low density polyethylene, medium density polyethylene, high density polyethylene, polyethylenes comprising copolymers of ethylene with one or more alpha-olefins (a-olefins) such as butene-1, hexene-1, octene-1, or the like as a comonomer, linear low density polyethylene, very low density polyethylene, ultra low density polyethylene, ethylene/propylene copolymers, polypropylene, propylene/ethylene copolymer, polyisoprene, polybutylene, polybutene, poly-3-methylbutene-1, poly-4-methylpentene-1, ionomers and the like.

“Polyester” refers to homopolymers or copolymers having an ester linkage between monomer units which may be formed, for example, by condensation polymerization reactions between a dicarboxylic acid and a glycol. The dicarboxylic acid may be linear or aliphatic, i.e., oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, and the like; or may be aromatic or alkyl substituted aromatic, i.e., various isomers of phthalic acid, such as paraphthalic acid (or terephthalic acid), isophthalic acid and naphthalic acid. Specific examples of alkyl substituted aromatic acids include the various isomers of dimethylphthalic acid, such as dimethylisophthalic acid, dimethylorthophthalic acid, dimethylterephthalic acid, the various isomers of diethylphthalic acid, such as diethylisophthalic acid, diethylorthophthalic acid, the various isomers of dimethyinaphthalic acid, such as 2,6-dimethylnaphthalic acid and 2,5-dimethylnaphthalic acid, and the various isomers of diethyinaphthalic acid. The glycols may be straight-chained or branched. Specific examples include ethylene glycol, propylene glycol, trimethylene glycol, 1,4-butane diol, neopentyl glycol and the like. In one example a preferred embodiment of this invention, the first layer comprises polyethylene terephthalate copolymer and most preferable, biaxially-oriented polyethylene terephthalate copolymer.

“Polyvinyl chloride” commonly abbreviated PVC refers to homopolymers or copolymers having at least a vinyl chloride repeating unit within the polymer backbone. Polyvinyl chloride may be formed, for example, by free-radical polymerization a vinyl chloride monomer. PVC is similar to polyethylene, but on every other carbon in the backbone chain, one of the hydrogen atoms is replaced with a chlorine atom.

The amorphous thermoplastic matrix of the present invention is not, of course, limited to any of the examples provided above. Preferred embodiments of the present invention have a light-diffusive film and light-absorption film where each includes a thermoplastic matrix comprising polyolefin, particularly, polyethylene and polypropylene, polyester or polyvinyl chloride matrix. In a more preferred embodiment of the present invention, the both the light-diffusive film and light-absorption film comprising a thermoplastic matrix that includes polyvinyl chloride.

According to the present invention, the light-diffusive film is a lens-free, flexible monolayer or multilayer film having a substantially smooth first surface and an opposing substantially smooth second surface and comprises a wax-free amorphous thermoplastic matrix having a plurality of light-diffusing particle dispersed therein. The light-diffusive film according to the present invention will exhibit a visible light transmittance of between 60 to 80% and a visible light absorbance of between 0 to 15% as measured in accordance with European Norms EN410 test procedures. Generally, the light-diffusive layer will have a milky or frosted translucent appearance. The wax-free amorphous thermoplastic matrix is obtained by molding the material along with the desired amount of light-diffusing particles into a sheet-like form by methods known in the art which include, but are not limited to, for example, calendaring, extrusion, co-extrusion, injection molding, etc. The light diffusion capability of the light-diffusive film can be controlled by the selection of thermoplastic matrix material and light-diffusing particles, and the relative amounts of the light-diffusing particles present in the film.

The light-diffusing particles according to the present invention may include, but are not limited to, for example, organic particles, such as styrene resin particles, silicone resin articles, acrylic resin particles, and methacryl-styrene copolymer particles, inorganic particles, such as barium sulfate, calcium carbonate particles, silicon dioxide particles and the like, and metallic particles, such as aluminum and aluminum hydroxide, titanium oxide and the like. The light-diffusing particles of the present invention preferably include inorganic particles or inorganic particles and metallic particles, more preferably include barium sulfate particles, and most preferably include barium sulfate particles and aluminum particles. The light-diffusing particles may be dispersed in the light-diffusive film in any amount desired. A preferred amount of barium sulfate particles dispersed in the light-diffusive film is between 15 to 20% by weight relative to the entire weight of the layer. The preferred amount of aluminum particles present in the light-diffusive layer is preferably between 0 to 1.0% and more preferably, between 0.4 to 0.8% by weight relative to the entire weight of the layer. The thickness of the light-diffusive film is not particularly restricted, however a preferred range of thickness is between 25 to 250 microns, more preferably between 40 to 150 microns, and most preferably, between 50 to 100 microns.

The rear-projection screen according to the present invention is preferably constructed such that the light-diffusive film is an image receiving surface. Examples of suitable light-diffusive films for use in the present invention include those sold under the following trademarks and trade names: MACal® Glass Décor 700 series of films which are commercially available from MACtac Europe SA, Soignies, Belgium; Multi-fix series 5600 films which are commercially available from Multi-fix NV, Genk, Belgium; Hexis® S 5DP series of films which are commercially available from Hexis SA, Frontignan, France; and Avery® Dusted Glass Film which is commercially available from Avery Dennison Company, Graphics Division, Hazerswoude, The Netherlands.

According to the present invention, the light-absorption film is a flexible monolayer or multilayer film having a first surface and an opposing second surface and comprises an amorphous thermoplastic matrix having a plurality of light-absorbing particle dispersed therein. A light-absorption film according to the present invention will exhibit a visible light transmittance of between 35 to 60% and a visible light absorbance of between 40 to 60% as measured in accordance with European Norms EN410 test procedures. Generally, the light-absorption layer will be a colored transparent film.

The light-absorbing particles according to the present invention are any material that can absorb light uniformly and/or selectively and may include, for example, any organic or inorganic colorants or pigments. The term “colorant” refers to any particulate material which exhibits hue, chroma and/or value and may include any conventional colorant such as, for example, Toluidine Blue, Brillant Acid Blue, Cyanine Blue, First Light Red, Super Chrome Yellow, Ethyl Orange and others such as Titanium oxide, carbon black, cadmium red, barium yellow, cobalt green, manganese violet and other inorganic pigments, such as, Vulcan Orange, Lake Red, and azo pigments, nitroso pigments, nitro pigments, basic dye Lakes, acidic dye Lakes, phthalocyanine pigments, fluorescent pigments, etc. The light-absorbing particles used are not, of course, limited to the above and may be added to and dispersed into the thermoplastic matrix by the same manner as described above for the light-diffusing particles of the light-diffusive film. The light-absorbing particles preferably include carbon black particles, graphite particles, metal salt particles, such as black iron oxide particles, colored organic particles and colored glass beads, and more preferably, carbon black particles. The light-absorbing particles may be dispersed in the light-absorption film in any amount desired. The preferred amount of carbon black particles present in the light-absorption film is between 0.05 to 0.5% and more preferably between 0.05 to 0.3% by weight relative to the entire weight of the layer. The light absorption capability of the light-absorption film can be controlled by the selection of thermoplastic matrix material and light-absorbing particles, and the relative amounts of the light-absorbing particles present in the film. The thickness of the light-absorption film is not particularly restricted, however a preferred range of thickness is between 25 to 250 microns, more preferably between 40 to 150 microns, and most preferably, between 50 to 100 microns.

The rear-projection screen according to the present invention is preferably constructed such that the light-diffusive film is an ambient light or sunlight receiving surface. Examples of suitable light-diffusive films for use in the present invention include those sold under the following trademarks and trade names: Hexis® AUTO 20 CH and AUTO 35 CH series of films which are commercially available from Hexis SA, Frontignan, France; Solar Zone Alpha 36 films which are commercially available from Hanita Coatings, Kibbutz Hanita, Israel; 3M Scotchtint™ FX series of films which are commercially available from 3M Company, St Paul, Minn., U.S.A.; and Llumar Solar Control Films which are commercially available from CPFilms, Inc., Martinsville, Va., U.S.A.

Although specific embodiments of the present invention will now be described with reference to the drawings, it should be understood that such embodiments are by way of example only and merely illustrative of but a small number of the many possible specific embodiments which can represent applications of the principles of the present invention.

A conventional light-diffusive type rear-projection screen10is illustrated inFIGS. 1aand1bhaving an image receiving surface (or rear viewing surface)11and a front viewing (or ambient light or sunlight receiving) surface12. As shown by the arrows13, the projected image light from a light source or projector is incident on the image receiving surface11of the screen and observer A views the reflected image designated by dotted-line arrows14from surface11. At the same time, observer B views the transmitted image designated by dotted-line arrows15as it passes through the screen onto surface12. InFIG. 1a, ambient light, typically present inside of a building, is shown by the dashed-line arrow16, with the arrow indicating the direction of the incident light. The manner in which such ambient light can be reflected from the surface12before it enters screen10is designated schematically by the weighted dotted-line arrow17. A small portion of the reflected ambient light17will be directed from surface12towards observer B and will cause some obscuring of the transmitted image15. A small portion of the ambient light incident on the viewing surface12is diffused or refracted upon entry into screen10and is scattered within the screen. A portion of this ambient light is then transmitted through screen10and is directed back towards the observer A as designated by weighted dotted-line arrow18. This portion of ambient light18will cause some interference with the viewing of the reflected image14by observer A. InFIG. 1b, sunlight, typically present outside of a building, is shown by the weighted dashed-line arrow16′, with the arrow indicating the direction of the incident light. The manner in which such sunlight can be reflected from the surface12before it enters screen10is designated schematically by the weighted dotted-line arrow17′. A small portion of the sunlight incident on the viewing surface12is diffused or refracted upon entry into screen10and is scattered within the screen. A portion of this sunlight is transmitted through the screen to surface11and is directed back towards the observer A as designated by weighted dotted-line arrow18′. As is illustrated, when diffusion-type rear-projection screens are placed on an exterior window or are exposed to sunlight, a relatively large amount of the sunlight returns or reflects back to the observer B, as indicated by weighted dotted-line arrow17′. This will cause the transmitted image15to be more obscured when viewed by observer B. Additionally, a relatively large amount of sunlight passes through the screen and is directed towards observer A, as indicated by the weighted dotted-line arrow18′. This will also cause the reflected image14to be more obscured when viewed by observer A. This results in very poor image quality, particularly with respect to low image contrast for observers on both sides of the rear-projection screen.

A conventional light-absorption screen10′ is illustrated inFIG. 2. The projected image light is incident on the image receiving surface11of the screen and observer A views the reflected image designated by dotted-line arrows14from surface11. At the same time, observer B views the transmitted image designated by shortened dotted-line arrow15as it passes through the screen onto surface12. Sunlight is shown by the weighted dashed-line arrow16′ with the arrow indicating the direction of the incident light. The manner in which such sunlight can be reflected from the surface12before it enters screen10is designated schematically by the weighted dotted-line arrow17′. A portion of the reflected sunlight17′ will be directed from surface12towards observer B and will cause some obscuring of the transmitted image15. A small portion of the sunlight incident on the viewing surface12is diffused or refracted upon entry into screen10′ and is scattered within the screen. A portion of this sunlight is then transmitted through screen10′ and is directed back towards the observer A as designated by shortened dotted-line arrow18′. This portion of sunlight will cause some interference with the viewing of the reflected image14by observer A. As is illustrated, when a light-absorption screen is used as a rear-projection screen, a relatively large portion of the projected image light will be absorbed by screen10′. Consequently, a relatively small amount of image will be transmitted through screen10′ as designated schematically by shortened dotted-line arrow15. This results in very poor image quality, particularly with respect to low image brightness for observer B.

The inventive screen20shown inFIG. 3has a light-diffusive film21applied to a light-absorption film22. As depicted, a preferred embodiment of the present invention is shown having the light-diffusive film21facing the light source to receive the projected image thereon and the light-absorption film22facing sunlight in order to absorb the same. As shown by the arrow13, the projected image light from a light source is incident on the light-diffusive film21and observer A views the reflected image designated by dotted-line arrows14. At the same time, observer B views the transmitted Image designated by dotted-line arrows15as it passes through the screen. Sunlight is shown by the weighted dashed-line arrow16′, with the arrow indicating the direction of the incident light. The manner in which such sunlight can be reflected from the light-absorption film22before it enters screen20is designated schematically by the shortened dotted-line arrow17′. As is illustrated, when a rear-projection screen according to the present invention is placed on an exterior window or is exposed to sunlight, a large portion of sunlight is absorbed which results in a relatively small amount of sunlight being both reflected as designated schematically by the shortened dotted-line arrow17′ and transmitted through screen20. Moreover, there is less reflected sunlight to obscure the transmitted image seen by observer B and less transmitted sunlight to obscure the reflected image seen by observer A. Additionally, when a rear-projection screen according to the present invention is used in this manner, there is no interference of the transmitted image by the light-absorption film through the screen. Consequently, there is improved image contrast and image brightness for observers on both sides of the rear-projection screen20.

FIG. 4ashows an enlarged schematic cross-section of one embodiment of the inventive rear-projection screen30. Screen30includes a light-diffusive film31and a light-absorption film33. Film31has a first surface31aand an opposing second surface31band includes a plurality of light-diffusing particles32embedded and dispersed therein. Film33has a first surface33aand an opposing second surface33band includes a plurality of light-absorbing particles34embedded and dispersed therein. As illustrated, the second surface31bof film31is affixed to first surface33aof film33which can be accomplished by fusing these surfaces together under heat and pressure.

FIG. 4bshows an enlarged schematic cross-section of another embodiment of the inventive rear-projection screen40. Screen40includes a light-diffusive film31, a light-absorption film43and an adhesive45. Adhesive45may comprise any transparent pressure sensitive adhesive and may include a repositionable transparent pressure sensitive adhesive. Preferably, adhesive45comprises an acrylic-based transparent pressure sensitive adhesive. Film41has a first surface41aand an opposing second surface41band includes a plurality of light-diffusing particles32embedded and dispersed therein. Film43has a first surface43aand an opposing second surface43band includes a plurality of light-absorbing particles34embedded and dispersed therein. As illustrated, adhesive layer45joins second surface41bof film41to first surface33aof film33.

FIGS. 5aand5bshow enlarged schematic cross-sections of embodiments of the inventive rear-projection screen capable of being mounted to the surface of a planar transparent rigid substrate or between two planar transparent rigid substrates. As shown inFIG. 5a, a rear-projection screen50may be adapted to be temporarily or permanently mounted to a planar transparent rigid substrate51such as, for example, a pane glass. Screen50is substantially identical to screen30as depicted inFIG. 4aand further includes a transparent pressure sensitive adhesive45positioned between the second surface33bof light-absorption film33and rigid substrate51.FIG. 5billustrates screen60adapted to be permanently mounted between two planar transparent rigid substrates51and52. Screen60is substantially identical to screen50and further includes a second transparent pressure sensitive adhesive46positioned between the first surface31bof light-diffusive film31and rigid substrate52. It is contemplated that adhesive46may be the same or different transparent pressure sensitive adhesive as adhesive45.

FIGS. 6aand6bshow enlarged schematic cross-sections of alternative embodiments of the inventive rear-projection screen capable of being mounted to the surface of a planar transparent rigid substrate or between two planar transparent rigid substrates. InFIG. 6a, screen70includes a light-diffusive film31affixed to a first side of rigid substrate51via a transparent pressure sensitive adhesive45and a light-absorption layer33affixed to the opposite second side of rigid substrate51via a second transparent pressure sensitive adhesive46. InFIG. 6b, screen80is adapted to be mounted between two planar transparent rigid substrates52and53. As depicted, screen80is substantially identical to screen70and further comprises a third transparent pressure sensitive adhesive47disposed between the second surface33bof light-absorption film33and rigid substrate53, and a fourth transparent pressure sensitive adhesive48disposed between rigid substrate52and the first surface31aof light-diffusive film31. It is contemplated that transparent pressure sensitive adhesives45,46,47and48may be the same or different transparent pressure sensitive adhesives. It is further contemplated that transparent pressure sensitive adhesives45,46,47and48may be applied as a coating over an entire surface of a film or substrate or portions thereof, or as individual spots on a surface of the film or substrate.

Turning now toFIG. 7, a flowchart100depicts one technique for creating a rear-projection screen in accordance with embodiments depicted inFIGS. 5aand5b. In this embodiment, the following steps are contemplated in this order:Step101, providing a light-diffusive flexible first film having a substantially smooth first surface and an opposing substantially smooth second surface, whereby the light-diffusive film exhibits a visible light transmittance of between 60 to 80%, a visible light absorbance of between 0 to 15% and is both wax-free and lens-free;Step102, providing a light-absorptive flexible second film having a first surface and an opposing second surface, whereby the light-absorptive film exhibits a visible light transmittance of between 35 to 60% and a visible light absorbance of between 40 to 60%;Step103, laminating said second surface of the light-diffusive film to the first surface of the light-absorptive film to form a laminate, whereby the laminate exhibits a visible light transmittance of between 25 to 50% and a visible light absorbance of between 35 to 60%.

After step103, this method for creating a rear-projection screen may further include the following optional steps as indicated by the dashed-line arrows:Step104, applying a transparent pressure sensitive adhesive to said second surface of the light-diffusive film, andStep105, affixing the laminate to a planar transparent rigid substrate such that the adhesive is positioned between the laminate and the substrate, and the light-diffusive film is in direct contact with the light-absorptive film.

Alternatively after step103, this method for creating a rear-projection screen may further include the following optional steps of:Step104′, applying a transparent pressure sensitive adhesive to the first surface of the light-diffusive film, andStep105′, affixing the laminate to and between a first planar transparent rigid substrate and to a second planar transparent rigid substrate, such that the light-diffusive film is in direct contact with the light-absorptive film.

Turning now toFIG. 8, a flowchart200depicts one technique for creating a rear-projection screen in accordance with the embodiment depicted inFIG. 6a. In this embodiment, the following steps are contemplated in this order:Step201, providing a light-diffusive flexible film having a substantially smooth first surface and an opposing substantially smooth second surface, whereby the light-diffusive film exhibits a visible light transmittance of between 60 to 80%, a visible light absorbance of between 0 to 15% and is both wax-free and lens-free;Step202, providing a light-absorptive flexible second film having a first surface and an opposing second surface; whereby light-absorptive film exhibits a visible light transmittance of between 35 to 60% and a visible light absorbance of between 40 to 60%;Step203, applying a transparent pressure sensitive first adhesive to the second surface of the light-diffusive film;Step204, applying a transparent pressure sensitive second adhesive to the first surface of the light-absorptive film:Step205, providing a planar transparent rigid substrate having a first surface and an opposing second surface; andStep206, affixing the first adhesive to the first surface of the substrate and affixing the second adhesive to the second surface of the substrate to form a laminate; such that the laminate exhibits a visible light transmittance of between 25 to 50% and a visible light absorbance of between 35 to 55%.

Turning now toFIG. 9, a flowchart300depicts one method for displaying a projected image onto a window with the use of a rear-projection screen in accordance with the present invention. In this embodiment, the following steps are contemplated in this order:Step301, providing a projector for presenting an image;Step302, providing a lens-free flexible light-diffusive first film having a substantially smooth first surface and an opposing substantially smooth second surface, wherein the light-diffusive film comprises a wax-free amorphous thermoplastic matrix selected from the group consisting of polyvinyl chloride, polyester and polyolefin, a plurality of inorganic light-diffusing particles dispersed therein in an amount of between 15 to 20% by weight relative to the entire weight of the film and a plurality of metallic light-diffusing particles dispersed therein in an amount of between 0 to 1.0% by weight relative to the entire weight of the film;Step303, providing an opposing light-absorptive flexible second film having a first surface and an opposing second surface, and comprising a thermoplastic matrix selected from the group consisting of polyvinyl chloride, polyester and polyolefin; and a plurality of light-absorbing colorant particles dispersed therein in an amount of between 0.05 to 0.5% by weight relative to the entire weight of the film;Step304, providing a transparent pressure sensitive first adhesive:Step305, positioning the light-diffusive film, the light-absorptive film, the first adhesive on a window to form a laminate such that either:i) said first surface of the light-absorptive film is in direct contact with the second surface of light-diffusive film and the second surface of the light-absorptive film is in direct contact with the first adhesive, and the first adhesive is in contact with an interior surface of the window; orii) the first adhesive is in direct contact with both said second surface of the light-diffusive film and an interior surface of the window, and a second transparent pressure sensitive adhesive is in direct contact With both the first surface of the light-absorptive film and an exterior surface of the window; andStep306, projecting an image from the projector onto the laminate such that the image enters the first surface of the light-diffusive film and exits the second surface of the light-absorptive film; such that the laminate exhibits a visible light transmittance of between 25 to 50% and a visible light absorbance of between 35 to 55%.

The following Examples illustrate various aspects of the present invention. It is to be understood that the present invention is defined by the appended claims and not specific details of the Examples.

REAR-PROJECTION SCREEN EXAMPLES

Comparative Example 1

Comparative example 1 was a light-diffusive film similar to the one described inFIG. 1. The light-diffusive film was a MACal® Glass Décor 700 film obtained from MACtac Europe SA which included a translucent monolayer film having amorphous polyvinyl chloride matrix with between 15 to 20% by weight relative to the entire weight the film of barium sulfate particles and between 0.4 to 0.8% by weight relative to the entire weight the film of aluminum particles each incorporated and dispersed therein. The film had an approximate overall thickness of about 75 to 80 microns.

Comparative Example 2

Comparative example 2 was a monolayer light-diffusive film identical to that described for Comparative Example 1, except that about 0.2% by weight relative to the entire weight the film of carbon black was incorporated into the polyvinyl chloride matrix.

Comparative Example 3

Comparative example 3 was a monolayer light-absorptive film similar to the one described inFIG. 2. In this example, the light-absorptive film consisted of a polyethylene terephthalate matrix having 0.2% by weight relative to the entire weight the film of carbon black incorporated therein.

Comparative Example 4

Comparative example 4 was similar to Comparative Example 3, except for an extra light-absorptive film having a identical composition was added. The two light-absorptive films were fused together by heat and pressure to form a two-ply laminate.

Comparative Example 5

Comparative example 5 was a monolayer light-absorptive film similar to the one described inFIG. 2. The light-absorptive film consisted of a polyvinyl chloride matrix with about 0.2% by weight relative to the entire weight the film of carbon black incorporated therein.

Example 1 included a light-diffusive film and a light-absorptive film similar to the laminate described inFIG. 3. The light-diffusive film was identical to that described for Comparative Example 1. The light-absorptive film was a transparent monolayer film having a matrix of amorphous polyethylene terephthalate and about 0.2% by weight relative to the entire weight of the film of carbon black incorporated therein. The light-diffusive and light-absorptive films were adhesively laminated together by use of a transparent acrylic pressure sensitive adhesive to form a two-ply laminate.

Example 2 was similar to Example 1, except that an extra light-absorptive film having an identical composition as that described in Example 1 was added. The light-diffusive and light-absorptive films were fused together by heat and pressure form a three-ply laminate.

Example 3 was similar to Example 2, except that an extra light-absorptive film having an identical composition as that described in Example 1 was added. The light-diffusive film and light-absorptive films were fused together by heat and pressure form a four-ply laminate.

Example 4 was similar to Example 1, except for the light-absorptive film was a transparent monolayer film having a matrix of amorphous polyvinyl chloride with between 0.05 to 0.3% by weight relative to the entire weight of film of carbon black incorporated therein. The light-diffusive and light-absorptive films were fused together by heat and pressure to form a two-ply laminate.

Example 5 was identical to Example 4, except that the laminate was mounted onto a 4 mm pane of glass similar to that described inFIG. 5a.

Table 1 illustrates the various spectral properties of the rear-projection screens described above for Comparative Examples 1, 2, 3, 4 and 5, and Examples 1, 2, 3, 4, and 5. Prior to measuring the spectral properties, a layer of pressure sensitive adhesive applied to the surface of each screen. It will be understood that the spectral properties were measured in accordance with European Norm EN 410.

It will be apparent to those skilled in the art that modifications and additions can be made to the various embodiments described above, without departing from the true scope and spirit of the present invention. It should be understood that this invention is not intended to be unduly limited by the illustrative embodiments set forth herein and that such embodiments are presented by way of example only with the scope of the invention intended to be limited only by the claims set forth herein as follows.