Ambient light absorbing screen

Abstract

A projection screen for receiving projector light from a projector facing direction includes a substrate having a plurality of features. Each of the features includes a reflective surface oriented to the projector facing direction. Each of the reflective surfaces is curved in a first direction to provide a desired horizontal viewing angle, and is curved in a second direction to provide a desired vertical viewing angle.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a diagrammatic side view of an embodiment of a front projection screen with a textured surface to which material has been selectively added to make it reflective.

FIG. 1B is a diagrammatic side view of an embodiment of a rear projection screen with a transparent substrate having a textured surface to which material has been selectively added to make it reflective.

FIG. 1C illustrates another embodiment of a rear projection screen or LCD display.

FIG. 2 is an isometric view of an embodiment of a textured substrate.

FIG. 3 is a photographic image of an embodiment of a substrate on which a low angle deposition has been performed.

FIG. 4 schematically depicts an embodiment of a deposition system for low angle deposition of a material onto a substrate.

FIGS. 5 and 6 schematically depict another embodiment of a deposition system for low angle deposition of a material onto a substrate.

FIG. 7 diagrammatically depicts a method of jetting absorptive or reflective elements onto exposed surfaces of a featured substrate.

FIG. 8 illustrates another embodiment of a screen substrate, in which a first layer of light absorbing material is selectively deposited on portions of the surface features of the screen substrate, which will be faced toward a source of ambient light, and a second layer of reflective material is selectively deposited on portions of the surface features facing the projector.

FIG. 9 is a diagram illustrating a front view of a portion of an ambient light rejecting projection screen according to one embodiment of the present invention.

FIG. 10 is a diagram illustrating a side view of the projection screen portion shown in FIG. 9 according to one embodiment of the present invention.

FIG. 11 is a diagram illustrating a projection screen with substrate features like those shown in FIGS. 9 and 10 according to one embodiment of the present invention.

FIG. 12 is a flow diagram illustrating a method of creating a projection screen according to one embodiment of the present invention.

FIG. 13 is a flow diagram illustrating a method of using a projection screen for receiving image light from an image source according to one embodiment of the present invention.

Claims

1. A projection screen for receiving projector light from a projector facing direction, the screen comprising: a substrate having a plurality of features, each of the features including a reflective surface oriented to the projector facing direction, each of the reflective surfaces being curved in a first direction to provide a desired horizontal viewing angle, and curved in a second direction to provide a desired vertical viewing angle.

2. The projection screen of claim 1, wherein each of the features is an arched conic section having a base and the reflective surface, and wherein the reflective surface extends from the base to a tip of the conic section.

3. The projection screen of claim 2, wherein the base of each of the features is an absorptive surface that is oriented substantially perpendicular to a plane of the projection screen.

4. The projection screen of claim 1, and further comprising a plurality of absorptive recesses formed in the substrate.

5. The projection screen of claim 4, wherein each of the absorptive recesses includes a plurality of light absorbing surfaces, and wherein the plurality of features are separated from each other by the plurality of absorptive recesses.

6. The projection screen of claim 5, wherein the plurality of features and the plurality of recesses are uniformly positioned in two dimensions across a surface of the substrate.

7. The projection screen of claim 5, wherein each of the absorptive recesses is generally pyramidal in shape.

8. The projection screen of claim 1, wherein the plurality of features is formed on a hexagonal grid.

9. The projection screen of claim 1, wherein the substrate has been embossed to form the plurality of features.

10. The projection screen of claim 1, wherein the substrate is a light absorbing plastic film that has been embossed to form the plurality of features.

11. The projection screen of claim 1, wherein the substrate is fabricated of a light-absorbing material, and the reflective surfaces are formed by depositing light-reflective material at a glancing angle onto the substrate.

12. The projection screen of claim 1, wherein the plurality of features have an average feature length and width in a range from about 75 microns to 500 microns.

13. A method of creating a projection screen, comprising: forming a plurality of features on an absorptive substrate, each feature including a first surface curved in a first direction to provide a desired horizontal viewing angle, and curved in a second direction to provide a desired vertical viewing angle;forming a plurality of absorptive recesses in the substrate positioned between the plurality of features; anddepositing a reflective material on the first surface of each of the features.

14. The method of claim 13, wherein each of the features is an arched conic section having a base and the first surface, and wherein the first surface extends from the base to a tip of the conic section.

15. The method of claim 14, wherein the base of each of the features is an absorptive surface that is oriented substantially perpendicular to a plane of the projection screen.

16. The method of claim 13, wherein each of the absorptive recesses is substantially pyramidal in shape.

17. The method of claim 13, wherein the plurality of features and the plurality of recesses are formed on a hexagonal grid.

18. The method of claim 13, wherein the plurality of features and plurality of recesses are formed by embossing.

19. The method of claim 13, wherein the reflective material is deposited at a glancing angle onto the substrate.

20. A method of using a projection screen for receiving image light from an image source,.the method comprising: providing a substrate having a plurality of features, each of the features including a reflective surface, each of the reflective surfaces being curved in a first direction to provide a desired horizontal viewing angle, and curved in a second direction to provide a desired vertical viewing angle;positioning the image source at a position corresponding to a shape and orientation of the reflective surfaces; anddirecting image light from the image source onto the reflective surface of the features.