Patent Publication Number: US-2002011380-A1

Title: Projection screen and projection screen system

Description:
[0001] This application is related to commonly owned U.S. patent application Ser. No. 08/969,132, now U.S. Pat. No. 5,923,002, the complete contents of which are herein incorporated by reference. This application is also related to commonly owned U.S. Patent Application having Ser. No. 09/429,602, filed Oct. 28, 1999, entitled “Fabric Retainer for Acoustic Structure and Methods of Installation,” the complete contents of which are herein incorporated by reference. 
    
    
     
       TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION  
       [0002] The present invention relates generally to a projection screen system for a room. More particularly, a projection screen system is disclosed which provides for the adjustment of room acoustics.  
       BACKGROUND OF THE INVENTION  
       [0003] Acoustical treatment of enclosed spaces has long been recognized as desirable. It is generally known that a room or the like may be acoustically treated, or “tuned,” by selectively placing patterns of acoustical material on the interior walls. Tuning enhances or otherwise controls the sound quality within the room, such as the sound quality of a home theatre system.  
       [0004] Arrangements of acoustical treatment generally include segments of acoustical material mounted on the walls, ceilings, or other surfaces of a room. The acoustical material may, for example, selectively diffuse, reflect, or absorb sound. After the acoustical material is mounted on the wall, it is covered by a fabric. The fabric may be selected to enhance the aesthetic appeal of the room, such as by covering the acoustical material with fabrics of differing patterns and colors. In addition, the fabric keeps dirt and dust from collecting in the acoustical material.  
       [0005] Controlling room acoustics is desirable where sound quality is important, such as in a movie theater. A conventional theater includes a projection screen spaced from a wall, with insulation attached to a board clipped to the wall behind the projection screen. Batt insulation has been mounted behind a projection screen in this manner. The insulation is mounted on the wall in order to reduce the buildup of sound energy in the theater.  
       [0006] Another conventional projection screen system has a screen which is snap-stretched within a frame. The periphery of the screen includes grommets which engage hooks or snaps on the frame, thereby supporting the screen on the frame. Canvas is a conventional material for the screen. The acoustical absorption of the screen is altered by perforating the screen. However, perforated screens are undesirable because they have reduced light reflectivity, and a corresponding poorer video image quality. In addition, the conventional projection screen system requires a rigid frame and is relatively expensive.  
       [0007] U.S. Pat. No. 2,187,904 to Hurley shows a projection screen with a sound-transmitting screen area. Hurley&#39;s screen includes a light-reflecting area  12  surrounded by a light-absorbent mask  14 . The light-absorbent mask  14  has perforations which allow for the transmission of sound from behind the screen. The perforations do not provide tunability for the room. Further, the inclusion of the perforated light-absorbent mask  14  around the perimeter of the light-reflecting part  12  increases the size of the screen.  
       [0008] U.S. Pat. No. 2,710,335 to Wong shows a light diffusing and sound absorbent unit. Wong discloses a panel  21  which may be used to either reflect or absorb sound, and which selectively absorbs light.  
       [0009] The conventional projection arrangements do not disclose a projection screen which can be used to acoustically tune a room  
       [0010] U.S. Pat. No. 5,923,002 to McGrath et al. discloses acoustical material in the form of paneling, and methods of installing the paneling. The acoustical paneling is mounted on wall surfaces to change room acoustics, and is covered by fabric material  100 . The fabric material  100  is held within fabric retainers  96 , as shown in FIG. 10 of McGrath et al.  
       [0011] A projection screen system has not been integrated into a system of acoustic treatment.  
       [0012] Therefore, a projection screen system having tunability, which can be integrated into an acoustical treatment for a wall, is desirable.  
       SUMMARY OF THE INVENTION  
       [0013] The projection screen and projection screen system disclosed in this application overcome the above disadvantages and provide further advantages not contemplated by conventional devices. The present invention is therefore directed, in part, to a projection screen which is supportable at its edges within a system of retainer members. These retainer members are also suitable for supporting fabric for covering acoustical material disposed on a wall. The projection screen of the present invention can therefore be incorporated into a projection screen system which covers an entire wall, or a part of a wall.  
       [0014] The invention, in part, also provides a projection screen having screen material supported by a system of retainer members, into which the peripheral edges of the screen material are tucked. Acoustical material can be placed behind the projection screen in order to render the area covered by the screen tunable. The screen is flexible and is tautly mounted in the system of retainer members. Optionally the screen may be elastic in order to facilitate a smooth appearance once the screen is installed.  
       [0015] In addition to placing acoustical material behind the screen material to alter the acoustic characteristics of the room, the screen material itself can have variable acoustic properties. The screen material and the acoustical material are then selected to work in unison, so that specific frequency bands of sound are absorbed by each material.  
       [0016] All or a part of the remainder of the wall may be treated by acoustical material disposed outside the perimeter of the system of retainer members for the projection screen. This acoustical material is bordered by a second system of retainer members. The second system of retainer members supports the outermost edges of covering fabric which covers the acoustical material mounted on the wall around the projection screen. The interior edges of the covering fabric are tucked into the system of retainer members which supports the exterior edges of the screen material.  
       [0017] In this manner, all or a part of a wall including a projecting screen can be treated with acoustical material, forming a projection screen system for the wall. The entire wall can therefore be made tunable by the selection of specific acoustical materials for the projection screen and for the surrounding wall treatment, and by the selection of the screen material. The projection screen and the surrounding wall treatment present a flush surface, and form a smooth, integrated, projection screen system.  
       [0018] Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0019] The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:  
     [0020]FIG. 1 is a front view of a projection screen system according to the present invention;  
     [0021]FIG. 2 is a sectional view taken in the plane of line II-II in FIG. 1;  
     [0022]FIG. 3 is an enlarged view of the comer of the first retainer system;  
     [0023]FIG. 4 is a perspective view of a retainer according to the present invention;  
     [0024]FIG. 5 is a cross-sectional view of an alternative retainer according to the present invention;  
     [0025]FIG. 6 is a cross-sectional view of another retainer according to the present invention;  
     [0026]FIG. 7 is a partial perspective view of acoustical paneling according to the present invention;  
     [0027]FIG. 8 is a partial perspective view of another type of acoustical paneling according to the present invention; and  
     [0028]FIG. 9 is a partial perspective view of yet another type of acoustical paneling according to the present invention. 
    
    
     DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS OF THE INVENTION  
     [0029]FIG. 1 is a front view of an embodiment of a projection screen system according to the present invention. Projection screen system  10  includes a projection screen  12  including a first retainer system  14 , which serves as a frame for the projection screen  12 . The remainder of the wall is covered by wall treatment  16 , which renders the entire wall tunable. In FIG. 1, the first retainer system  14  is not visible due to the presence of screen material  24  and covering fabric  26 . When edges of the screen material  24  and the covering fabric  26  have both been installed in the first retainer system  14 , the perimeter of the projection screen  12  is visible only as a hairline joint  15 .  
     [0030] As shown in FIG. 1, the wall treatment  16  is disposed around the perimeter of the projection screen  12 . The covering fabric  26  of the wall treatment  16  is supported at its outer edges by a second retainer system  18 . The first retainer system  14  and the second retainer system  18  are comprised of elongated retainer members having retaining portions, which will be discussed with reference to FIGS. 2 and 4- 6 .  
     [0031]FIG. 2 is a sectional view taken in the plane of line II-II in FIG. 1. Reference numeral  22  indicates a cross-section of a retainer member constituting a part of the first retainer system  14 . The retainer member  22  supports exterior edges of the screen material  24 , and interior edges of the covering fabric  26 , within a retaining portion  30 . A retainer groove  32  allows access to the interior of the retainer  22 , through which the respective edges of the screen material  24  and the covering fabric  26  are tucked into a pocket  33  located near the base of the retainer member  22 .  
     [0032] Acoustical material is disposed on either side of the retainer member  22  and secured to a wall  28 . In FIG. 2, the acoustical material is shown as acoustical paneling  34  located behind the screen material  24 , and acoustical paneling  38  located behind the covering fabric  26 . It is to be understood that any acoustical material suitable for acoustically treating a wall is appropriate for use in the projection screen  12  and in the wall treatment  16 .  
     [0033] The projection screen  12  includes the acoustical paneling  34 , the screen material  24 , and the first retainer system  14 , which is formed by a series of retainer members  22 . The acoustical paneling  34  may be a single paneling element, or may include multiple paneling elements. In order to enhance the optical reflectivity of the projection screen  12 , an optically reflective mat  36  is laminated onto a surface of the acoustical paneling  34 . The reflective mat  36  is preferably made from a glass of a highly reflective color, such as white. The acoustical paneling  38  of the wall treatment  16  may also include a reflective mat  36 , but it is not required. It is preferable to use paneling of neutral color behind covering fabric  26 , to prevent any coloring from showing through the covering fabric  26 , which is known as “telegraphing” of color. Acoustical paneling  34  and  38  may be reversible in order to obtain differing acoustic tuning properties.  
     [0034] As can be seen with reference to FIGS. 1 and 2, the projection screen  12  integrated with wall treatment  16  allows an entire wall surface to be acoustically treated with a smooth, continuous projection screen system  10 . The airflow resistance of acoustical paneling  34  and  38  can be varied in order to reduce acoustic modal pressure peaks and nulls forming along the wall  28 . The airflow resistance of the acoustical paneling is varied by selecting panels of varying depth, layer types, and composition. Airflow resistance is varied depending upon the frequencies to be addressed. Preferred acoustical paneling will be discussed with reference to FIGS.  7 - 9  of this application.  
     [0035] In addition to varying the airflow resistance of acoustical paneling  34  and  38 , the acoustical properties of the screen material  24  can also be varied. The screen material  24  should be made of a flexible material which can withstand the installation process into the first retainer system  14 . Examples of such materials include polyester fiber material, elastic membranes, composite woven materials, rubbers, vinyls, and mixtures of synthetic rubbers. Other suitable materials may be heat shrinking polymer films which may be installed and then exposed to a heat source to shrink the screen to form a taut surface. The screen material  24  must either be optically reflective, or must have a surface which is treatable such that it can be rendered optically reflective. Examples of treatments for the surface of screen material  24  include a coating of small reflective glass beads, or reflective paint, or a combination thereof.  
     [0036] The treatment which affects the reflectivity of the screen material  24  may also affect the acoustic absorption characteristics of the screen material  24 . For example, applying different thicknesses and types of reflective paint to the surface of the screen material  24  can alter the airflow resistance of the screen material  24 . As the airflow is restricted, the screen material  24  becomes more of a low frequency diaphragmatic absorber. The airflow resistance of the screen material  24  can also be adjusted without regard to the optical reflectivity properties of the screen material  24 . For example, variable strips of airflow restrictive coatings could be applied to the screen material  24 . Any coating applied to the screen material  24  must be compatible with the flexibility of the screen material  24  during installation, and must not crack or flake off of the screen material  24 . The airflow resistance of the screen material may not only be altered, but it may be completely restricted, whereby the screen becomes a diaphragmatic absorber.  
     [0037] The acoustical paneling  34  and the screen material  24  are selected to act in unison in tuning the room. Specifically, the screen material  24  can be chosen to absorb a narrow or a wide bandwidth of frequencies which may be determined as problematic within the room. The acoustical paneling  34  is in turn selected which absorbs modal pressure peaks within a specified bandwidth influenced by the screen material  24 .  
     [0038] The wall treatment  16 , which includes acoustical paneling  38  and covering fabric  26 , is similarly constructed. Covering fabric  26  may be acoustically transparent, may include a degree of acoustic absorption prefabricated into the covering fabric  26 , or may be acoustically treated during installation. The acoustical paneling  38  can be varied in depth and cross-section. Preferred acoustical paneling will be discussed with reference to FIGS.  7 - 9 .  
     [0039] The following is a description of the assembly process for the projection screen system  10 . Acoustical paneling  34  and  38  is disposed in a pattern on wall  28 . First and second retainer systems  14  and  18  are also mounted in a desired pattern on the wall  28 . A pattern of screen material  24  approximating the size of the projection screen  12  is placed over the first retainer system  14 . The edges of the screen material  24  are then tucked into the first retainer system  14  in the retaining portions  30 . This is known as the “preliminary tuck,” and any excess screen material protruding from the retainer system is cut off. Next, excess screen material  24  is tucked into the retaining portions  30  of first retainer system  14 . This is known as the “final tuck,” during which the screen is pulled taut. This can be done with a bladed tool resembling a spatula having a dull bladed edge.  
     [0040] The covering fabric  26  is similarly installed between the first retainer system  14  and the second retainer system  18 . If the retainer  22  shown in FIG. 2 is used as the cross-section for the first retainer system  14 , the covering fabric and the screen material  24  must both be tucked into a single retaining portion  30  of the retainer  22 .  
     [0041] The screen material  24  may be treated with a coating of optically reflective material, with a coating of material affecting the airflow resistance of the screen material, or both.  
     [0042] It is preferable that the first retainer system  14  have a rectangular shape with an essentially closed perimeter, so that the screen material  24  is supported along most of its periphery. However, retainer members of the first retainer system  14  can be arranged in any pattern, such as a square, polygon, etc., which is suitable for supporting screen material  24 . Also, the first retainer system  14  need not have an essentially closed perimeter, and gaps can be included in the first retainer system  14 . One example of a first retainer system  14  having a partially open perimeter could include two opposed rows of retainer members for supporting opposed edges of screen material  24 .  
     [0043]FIG. 3 is an enlarged view of the area indicated by reference numeral  20  in FIG. 1. FIG. 3 illustrates how two retainer members are joined at a comer of the first retainer system  14 . A first retainer member  44  and a second retainer member  46  are given 45° miter cuts at the joint site. A small gap  48  can be left between the first and second retainer members.  
     [0044]FIG. 4 is a perspective view of an alternative retainer member according to the present invention. The retainer  400  is shown as an elongated member having a base wall  402 . Base wall  402  has an exterior surface which may be attached to a support wall or structure. A first wall  404  extends from the base wall  402 , and an end portion  406  of the first wall  404  forms a part of a retaining portion  401  of the retainer  400   
     [0045] An interior wall  416  extends from the base wall  402  and terminates in a forked end. One branch of the fork is a retaining arm  410 , which forms part of the retaining portion  401 . Therefore, retaining portion  401  includes the end portion  406  of the first wall  404  and the opposed retaining arm  410 . A retainer groove  412  is defined by the end portion  406  and the retaining arm  410 . Once fabric or screen is inserted through the retainer groove  412 , it is gathered and retained within the storage pocket  414 .  
     [0046] The end portion  406  and the retaining arm  410  are provided with opposed retaining surfaces  460  and  462 , respectively. The retaining surfaces  460 ,  462  can be formed by, for example, rows or sets of teeth.  
     [0047] Locking portion  418  forms the second branch of the forked end of the interior wall  416 . The locking portion  418  extends from the forked end of the interior wall  416 , and includes a locking lip  422  which extends from a side of the locking portion  418 .  
     [0048] A second wall  424  extends from the base wall  402  and is spaced away from the first wall  404 . A chase  426  is defined between the interior wall  416  and the second wall  424 . The second wall  424  terminates in the locking portion  428 , which includes a locking lip  432  extending from a side of the locking portion  428 . The space between locking portions  418  and  428  defines an opening to the chase  426  through which wire, cabling, or any other communication, speaker, and/or power lines can be placed in the chase  426 . The interior of retainer  400  includes a box rib  450  which extends laterally from the interior wall  416  to the first wall  404 , thus defining a box section  452 .  
     [0049] In order to create a path between the exterior of the retainer and the chase  426 , one or more ports  490  may be formed in the first wall  404  and in the interior wall  416 . The ports  490  may be formed as needed during installation, or the retainer  400  may be manufactured so as to already include one or more ports  490  in the first wall  404  and/or the interior wall  416 .  
     [0050] The primary access to the chase  426  is provided by its open side located between the locking portions  418  and  428 . To cover the open side of the chase, the removable face cover  440  may be engaged with the locking portions  418 ,  428 . The removable face cover  440  is an elongated generally flat element which can engaged with respective locking portions  418 ,  428  to close the open side of the chase  426 . Locking lips  422  and  432  both preferably, but not necessarily, have chamfered surfaces  429 ,  439 .  
     [0051] The open side of the chase  426  also facilitates mounting of the retainer  400  onto a support surface, such as an underlying wall. A screw, a nail, or other fastener can be positioned through the opening of the chase  426  and driven through the base wall  402 . A stapler may also be positioned through the opening of chase  426  so that the retainer  400  can be stapled to a support surface. Alternatively, the retainer  400  can be secured to a support surface by an adhesive, such as “LIQUID NAILS” adhesive.  
     [0052]FIG. 5 is a cross-sectional view of an alternative retainer embodiment according to the present invention. The retainer  500  has two-way locking portions  521 ,  531 . Two-way locking portions  521 ,  531  allow for engagement with a face cover with locking projections which extend into the chase  526 . Decorative face cover  880  having locking projections  881  is shown engaged with two-way locking portions  521 ,  531 . Retainer  500  also includes fastener locators  570 .  
     [0053]FIG. 6 is a cross-sectional view of an alternative retainer embodiment according to the present invention. The retainer  600  has two separate retaining portions  601 , each having a retainer groove  612 .  
     [0054] The retainer embodiments disclosed in this application can made from, for example, molded or extruded (continuously molded) plastic. One suitable method of fabrication is extrusion of ABS or vinyl. Another suitable method is molding of ABS or vinyl. Any thermoplastic material which can be formed in the required configurations is considered appropriate for fabricating the embodiments in this application. Also appropriate are fiber-reinforced plastics (frp) or glass reinforced plastics (grp). Fire resistant materials may also be used to protect wiring mounted within the chase in the event of fire. Also, the retainers may be manufactured in selected colors for aesthetic reasons. It is expressly stated here that these methods are not the only methods by which the retainer assembly can be made, nor are the stated materials the only materials from which the retainer assembly can be made.  
     [0055] The relative heights and depths of the retainer embodiments illustrated are intended as representative of desirable retainer dimensions. However, the manipulation of retainer dimensions is considered to be within the scope of this invention.  
     [0056]FIG. 7 is a partial perspective view of acoustical paneling according to the present invention. Paneling  70  has a first surface  72  that is acoustically absorptive. The acoustically absorptive material can be any soft porous surface which absorbs sound energy. Paneling  70  also includes a rigid backing board  76  and a fibrous material  78  laminated thereto. The backing board  76  can be made from gypsum wall board, which can be installed using commercially available adhesive and/or mechanical fasteners.  
     [0057] A preferred acoustical paneling includes fibrous material  78  having a density of at least  3  pounds per cubic foot. Exemplary board of this type is manufactured by Owens Coming as an acoustical board product (700 SERIES BOARD). Other suitable materials for the fibrous material  78  include minimal and light duty fiberglass. A fiberglass mat  75  is optionally laminated to the outer surface of the fibrous material  78 .  
     [0058]FIG. 8 is a partial perspective view of another type of acoustical paneling according to the present invention. Paneling  80  has a rigid backing board  82  made from a commercially available open-cell melamine foam. The glass mat  86  is laminated over the foam  84 .  
     [0059]FIG. 9 is yet another type acoustical paneling according to the present invention. Paneling  90  has a rigid backing board  92  sandwiched between fibrous materials  94 . A glass mat  96  is laminated onto the fibrous material  94 . The rigid backing board  92  may advantageously be formed from any material which renders the paneling  90  diaphragmatic.  
     [0060] The acoustical paneling discussed with reference to FIGS.  7 - 9  are intended as exemplary of acoustical materials suitable for use in the projection screen system  10  according to the present invention. However, a wide variety of acoustical paneling could be employed in this invention.  
     [0061] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.