Patent ID: 7050229

Claim:
A method of manufacturing a rear-projection type screen having two or more overlapping sheet-like members selected from a group consisting of a Fresnel lens sheet, a Lenticular lens sheet having a hollow place formed therein, a front plate, and a protrusion integrally formed on the Fresnel lens sheet, said protrusion being fitted within the hollow place of the Lenticular lens sheet and protruding from a second overlapping sheet-like member of the two or more overlapping sheet-like members, the method comprising steps of: fabricating an inverted mold of the protrusion into a metal mold or a stamper; forming the two or more overlapping sheet-like members with the protrusion integrally formed thereon by injection molding using the metal mold or the stamper; and overlapping a first overlapping sheet-like member of the two or more overlapping sheet-like members and the second overlapping sheet-like member of the two or more overlapping sheet-like members to produce a gap between a front end of a lens on the first overlapping sheet-like member of the two or more overlapping sheet-like members and the second overlapping sheet-like member of the two or more overlapping sheet-like members, said gap extending over an entire screen image effective region of the screen, said protrusion of the Fresnel sheet and said hollow place of the Lenticular lens sheet being positioned outside the screen image effective area of the screen.