PROJECTION SCREEN AND PROJECTION SCREEN SYSTEM

Abstract

A projection screen and a projection screen system for an acoustic room. A projection screen includes a flexible screen material mounted within a system of retainers. The screen material is tautly retained within the a system of retainer members, and may be treated so that its airflow resistance is variable. Acoustical material is disposed on the wall behind the screen. Acoustical paneling is chosen according to the acoustical characteristics of the room, so that acoustical modal pressure peaks and nulls forming primarily along the length of the room can be reduced. The projection screen can be surrounded by further acoustical material, so that the entire wall can be used to tune the room. The acoustical material surrounding the projection screen is mounted within a second retainer system in which covering fabric is retained.

Description

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'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.

Claims

1. A projection screen system for attachment to a wall, comprising: a projection screen including: a first retainer system; and screen material supported by said retainer system, the screen material being substantially reflective of incoming light; and a wall treatment for covering a remaining portion of said wall and attached to said first retainer system.

2. The projection screen system of claim 1, wherein the first retainer system includes a plurality of elongated retainer members arranged about a perimeter of the projection screen, each retainer member including a retaining portion and a storage compartment.

3. The projection screen system of claim 2, wherein the retaining portions of the retainer members include opposed retaining surfaces, the opposed retaining surfaces grippingly securing a portion of the screen material within the storage compartments of said retainer members.

4. The projection screen system of claim 1, wherein the screen material is made from a polyester fiber material.

5. The projection screen system of claim 1, wherein the screen material is elastic.

6. The projection screen system of claim 1, wherein the projection screen further includes: acoustical paneling for attachment to the wall between the screen material and the wall.

7. The projection screen system of claim 6, wherein the acoustical paneling includes an optically reflective mat layer.

8. The projection screen system of claim 1, wherein the wall treatment includes: a second retainer system for attachment to the wall, exterior to a perimeter of the first retainer system.

9. The projection screen system of claim 8, wherein the wall treatment further includes: acoustical paneling for attachment to the wall; and covering fabric, the covering fabric being attached to the first retainer system, and also attached to the second retainer system, the covering fabric extending between the two retainer systems and covering the acoustical paneling.

10. A projection screen for attachment to a wall, comprising: screen material which is substantially reflective of incoming light; a retainer system; and acoustical material, the acoustical material being disposable on one side of the screen material.

11. The projection screen of claim 10, wherein the acoustical material includes at least one acoustical panel, the at least one acoustical panel having a surface opposed to the screen material which is substantially reflective of incoming light.

12. The projection screen of claim 10, wherein the screen material is supported at its edges within the retainer system, the screen material being pulled taut and substantially flat.

13. The projection screen of claim 12, wherein the screen material is made from a polyester fiber material.

14. The projection screen system of claim 12, wherein the screen material is elastic.

15. The projection screen of claim 12, wherein the screen material is coated with one of a reflective paint, and a layer of glass beads.

16. The projection screen of claim 11, wherein the retainer system includes a plurality of elongated retainer members arranged about a perimeter of the projection screen, each retainer member including a retaining portion and a storage compartment, the screen material being supported at its edges by the retaining portions of the retainer members.

17. The projection screen of claim 9, wherein said covering fabric is acoustically transparent.

18. A method of assembling a projection screen system comprising: mounting a retainer system to a wall; mounting acoustical material to the wall; and supporting screen material in the retainer system, so that acoustical material is disposed between the screen material and the wall, the screen material being substantially reflective of incoming light.

19. The method of claim 18, wherein mounting a retainer system to a wall includes: providing a first retainer system; and mounting the first retainer system to the wall, the first retainer system forming a perimeter for said screen; and wherein supporting the screen material in the retainer system includes inserting edges of the screen material into the first retainer system.

20. The method of claim 19, wherein mounting a retainer system to the wall further includes: providing a second retainer system; mounting the second retainer system to the wall, the second retainer system at least partly surrounding the first retainer system on the wall.

21. The method of claim 19, wherein providing a first retainer system includes: providing retainer members having a retaining portion and a storage compartment, the retaining portion having opposed retaining surfaces which retain a portion of said screen material.

22. The method of claim 19, wherein mounting acoustical material to the wall includes mounting acoustic paneling to the wall inside the perimeter of the first retainer system.

23. The method of claim 20, wherein mounting acoustical material to the wall includes mounting acoustic paneling to the wall between the first retainer system and the second retainer system.

24. The method of claim 23, further comprising: supporting covering fabric between the first retainer system and the second retainer system, the covering fabric having edges which are engaged with retainer grooves of the first and second retainer systems.

25. The method of claim 18, further comprising: applying a coating of material to the screen material, the coating of material changing the airflow resistance of the screen material.

26. The method of claim 18, further comprising: applying a coating of material to the screen material, the coating of material changing the optical reflectivity of the screen material.

27. A projection screen comprising: a retainer system for attachment to a wall, the retainer system including: at least one elongated retainer member, the at least one retainer member having opposed elongated retaining surfaces; and screen material supported by the retainer system, the screen material being substantially reflective of incoming light, with edges of the screen material being held between the opposed elongated retaining surfaces of the at least one elongated retainer member.

28. The projection screen of claim 27, wherein the at least one elongated retainer member further includes: a base wall, the base wall having a surface for engagement with the wall; opposed elongated retaining arms, the elongated retaining surfaces located on the opposed arms; and a storage compartment; wherein edges of the screen material are held in tension between the opposed elongated retaining surfaces, and extend into the storage compartment.

29. The projection screen of claim 28, wherein the screen material includes a reflective coating.

30. The projection screen of claim 27 wherein the screen material includes a heat shrink material.