U.S. patent application number 15/209075 was filed with the patent office on 2017-06-08 for tensioned projection screen apparatus.
The applicant listed for this patent is Draper, Inc.. Invention is credited to Kenneth M. Risher.
Application Number | 20170160630 15/209075 |
Document ID | / |
Family ID | 39332377 |
Filed Date | 2017-06-08 |
United States Patent
Application |
20170160630 |
Kind Code |
A1 |
Risher; Kenneth M. |
June 8, 2017 |
TENSIONED PROJECTION SCREEN APPARATUS
Abstract
A projection screen apparatus is disclosed for displaying an
image projected by a projector. The projection screen apparatus
includes a frame and a screen. The frame includes a plurality of
frame members and corner members.
Inventors: |
Risher; Kenneth M.; (Warren
Park, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Draper, Inc. |
Spiceland |
IN |
US |
|
|
Family ID: |
39332377 |
Appl. No.: |
15/209075 |
Filed: |
July 13, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14463097 |
Aug 19, 2014 |
9395615 |
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15209075 |
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13739339 |
Jan 11, 2013 |
8810909 |
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14463097 |
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|
12897484 |
Oct 4, 2010 |
8358464 |
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13739339 |
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12115351 |
May 5, 2008 |
7808702 |
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12897484 |
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11526951 |
Sep 26, 2006 |
7369310 |
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12115351 |
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10930255 |
Aug 31, 2004 |
7113332 |
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11526951 |
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10327421 |
Dec 20, 2002 |
6785047 |
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10930255 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G03B 21/56 20130101;
G03B 21/58 20130101; G03B 21/565 20130101; Y10T 29/49826 20150115;
F16M 13/02 20130101 |
International
Class: |
G03B 21/56 20060101
G03B021/56; F16M 13/02 20060101 F16M013/02 |
Claims
1-20. (canceled)
21. A projection screen apparatus for use with a projector
configured to project an image to be watched by a viewer, the
projection screen apparatus including: a projection screen having a
viewing surface configured to display the image to the viewer; a
frame supporting the projection screen and including a plurality of
frame members, the plurality of frame members including a top frame
member extending along a top edge of the projection screen, the top
frame member being a unitary extruded member including: a front
wall having a first side facing the viewer and a second side
opposite the first side, an upper portion including a first channel
extending the length of the top frame member, a lower portion
including a second channel extending the length of the top frame
member, and a plurality of ribs extending from the second side,
each rib defining an undercut groove, a first rib of the plurality
of ribs forming a top wall of the second channel, and a second rib
of the plurality of ribs being positioned between the first channel
and the second channel; and at least coupler coupling the
projection screen to the frame, a first coupler of the at least one
coupler coupling the top edge of the projection screen to the top
frame member with the top edge of the projection screen being
positioned rearward of the front wall of the top frame member, the
first coupler being a unitary extruded member including: a central
body; a lower circular portion extending from the central body, the
lower circular portion having an open end and a channel extending
the length of the first coupler, the top edge of the projection
screen being located in the channel extending the length of the
first coupler and the projection screen extends downward through
the open end of the lower circular portion; and an upper portion
including a first rib and a second rib, the first rib extending
from the central body in a first direction towards the first side
of the front wall of the top frame member, the first rib defining
with the central body an undercut groove, the second rib extending
from the central body in a second direction away from the first
side of the front wall of the top frame member, wherein the first
rib of the first coupler is positioned on top of a rib of the
plurality of ribs of the top frame member to couple the projection
screen to the top frame member, the undercut groove of the first
rib of the first coupler receiving the rib of the plurality of ribs
of the top frame member, the first channel of the top frame member
being sized and shaped to receive the first coupler for storage of
the first coupler when uncoupled from the projection screen.
Description
BACKGROUND AND SUMMARY OF THE INVENTION
[0001] This application is a continuation of U.S. patent
application Ser. No. 14/463,097, filed Aug. 19, 2014, which is a
continuation of U.S. patent application Ser. No. 13/739,339, filed
Jan. 11, 2013, now U.S. Pat. No. 8,810,909, which is a continuation
of U.S. patent application Ser. No. 12/897,484, filed Oct. 4, 2010,
now U.S. Pat. No. 8,358,464, which is a continuation of U.S. patent
application Ser. No. 12/115,351, filed May 5, 2008, now U.S. Pat.
No, 7,808,702, which is a continuation of U.S. patent application
Ser. No. 11/526,951, filed Sep. 26, 2006, now U.S. Pat. No.
7,369,310, which is a continuation-in-part of U.S. patent
application Ser. No. 10/930,255, filed Aug. 31, 2004, now U.S. Pat.
No. 7,113,332, which is a continuation of U.S. patent application
Ser. No. 10/327,421, filed Dec. 20, 2002, now U.S. Pat. No.
6,785,047, the disclosures of which are expressly incorporated by
reference herein.
[0002] The present invention relates to projection screens. More
particularly, the present invention relates to tensioned projection
screens.
[0003] According to one aspect of an exemplary embodiment of the
present disclosure, a projection screen apparatus for use with a
projector is provided that is configured to project an image to be
watched by a viewer. The projection screen apparatus includes a
projection screen having a viewing surface configured to display
the image to the viewer, The projection screen includes a plurality
of truncated corners. The projection screen apparatus further
includes a frame supporting the projection screen and including a
plurality of frame members. The projection screen apparatus further
includes a coupler coupling the projection screen to the frame.
[0004] According to another aspect of an exemplary embodiment of
the present disclosure, a projection screen apparatus for use with
a projector is provided that is configured to project an image to
be watched by a viewer. The projection screen apparatus includes a
projection screen having a viewing surface configured to display
the image to the viewer. The projection screen includes a first
perimeter edge, a second perimeter edge perpendicular to the first
perimeter edge, and a corner perimeter edge angled between the
first and second perimeter edges. The projection screen apparatus
further includes a frame supporting the projection screen and
including a plurality of frame members. The projection screen
apparatus further includes a coupler coupling the projection screen
to the frame.
[0005] According to yet another aspect of an exemplary embodiment
of the present disclosure, a projection screen apparatus for use
with a projector is provided that is configured to project an image
to be watched by a viewer. The projection screen apparatus includes
a projection screen having a viewing surface configured to display
the image to the viewer. The projection screen defines a plurality
of edges and has a length and a width. First and second edges of
the projection screen have lengths less than the length of the
projection screen. Third and fourth edges of the projection screen
have lengths less than the width of the projection screen. The
projection screen apparatus further includes a frame supporting the
projection screen and including a plurality of frame members. The
projection screen apparatus further includes a coupler coupling the
projection screen to the frame.
[0006] Additional features of the present invention will become
apparent to those skilled in the art upon consideration of the
following detailed description of an illustrated embodiment
exemplifying the best mode of carrying out the invention as
presently perceived.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] A detailed description particularly refers to the
accompanying figures in which:
[0008] FIG. 1 is a perspective view of a room showing a projector
projection an image on a projection screen apparatus according to
the present disclosure;
[0009] FIG. 2 is a perspective view of four corners of the
projection screen apparatus of FIG. 1;
[0010] FIG. 3 an exploded perspective view of a frame of the
projection screen apparatus of FIG. 1;
[0011] FIG. 4 is another exploded perspective view of the frame of
the projection screen apparatus of FIG. 1;
[0012] FIG. 5 is an exploded perspective view of a projection
screen and four couplers configures to couple the screen to the
frame;
[0013] FIG. 6 is a perspective view of a portion of the projection
screen apparatus showing two extended frame members coupled to a
corner member and the projection screen aligned to be coupled to
the frame and corner members by two screen coupler;
[0014] FIG. 7 is a cross-sectional view taken along line 7-7 of
FIG. 1 showing the coupler in a first location relative to the
frame member;
[0015] FIG. 8 is a cross-sectional view taken along line 8-8 of
FIG. 1 showing the coupler in a second location relative to the
frame member;
[0016] FIG. 9 is a view similar to FIG. 8 showing the coupler being
moved to a third position when a user pushes on the coupler with a
tool (in phantom); and
[0017] FIG. 10 is a cross-sectional view of the frame member and
coupler showing the coupler positioned within a channel of the
frame member for shipping.
DETAILED DESCRIPTION OF THE DRAWINGS
[0018] According to the present disclosure, a projection screen
apparatus 10 is provided to display images projected by a projector
12. Typically, projection screen apparatus 10 is mounted to a wall
14 of a structure, such as an entertainment room of a residence or
conference room of a business. As shown in FIG. 1, projector 12 is
positioned on the audience side of projection screen apparatus 10
to reflect back the images projected by projector 12 to an
audience. According to alternative installations, projector 12 is
positioned for a rear projection application on the back side of
projection screen apparatus 10 so that images projected by
projector 12 are displayed through projection screen apparatus 10
to the audience. In some installations, speakers (not shown) are
positioned behind the projection screen apparatus 10 so that the
sound is transmitted through projection screen apparatus 10.
[0019] As shown in FIG. 2, projection screen apparatus 10 includes
a perimeter frame 16 and a projection screen 18 tensioned on frame
16. As shown in FIG. 5, projection screen apparatus 10 further
includes a plurality of couplers 20 that couple projection screen
18 to frame 16 as shown in FIG. 7. According to the preferred
embodiment, each coupler 20 can be positioned at one of a number of
locations on frame 16. Depending on the location at which coupler
20 is positioned on frame 16, the level of tension in screen 18 is
greater or lesser.
[0020] Frame 16 includes four corner members 22 and four extended
frame members 24 extending between corner members 22 and forming a
junction 88, as shown in FIG. 6. Junction 88 includes a pair of
tubular channels 26, 28 and a pair of posts 30, 32. Each frame
member 24 is made of extruded aluminum and includes the pair of
channels 26, 28, The lengths of frame members 24 are dependent upon
the size of screen 18.
[0021] Each corner member 22 is made of ABS plastic and includes
the pair of posts 30, 32 sized to fit within respective channels
26, 28 of respective channels 26, 28 of respective frame members
24. During assembly, posts 30, 32 are slid into respective channels
26, 28 of each respective frame member 24 to define a rectangular
perimeter. Additional disclosure of a suitable projection screen
apparatus is provided in U.S. Provisional Patent Application No.
60/840,583, entitled "Tensioned Projection Screen," filed Aug. 28,
2006, to Steven E. Enochs, the disclosure of which is herein
incorporated by reference in its entirety.
[0022] Each frame member 24 further includes a fastener-receiving
channel 34 sized to receive a fastener 36, such as a screw. Each
corner member 22 includes a pair of fastener-receiving apertures 38
also sized to receive fastener 36. After posts 30, 32 are
positioned in channels 26, 28, fastener 36 are inserted into
apertures 38 and screwed into channels 34 to securely couple corner
members 22 to respective frame members 24.
[0023] Depending upon the length of frame members 24, an aluminum
brace 40 is provided that extends between opposite frame members
24. Each frame member 24 includes an open channel 42 and opposite
ends of brace 40 are positioned in channels 42. Preferably, brace
40 is under slight compression. According to alternative
embodiments, fasteners are provided to secure brace 40 on frame
members 24.
[0024] Before or after frame 16 is assembled, couplers 20 are
coupled to projection screen 18. Preferably before shipment of
projection screen apparatus 10, edges 44 of screen 18 are folded
over and sewn as shown in FIG. 5 to define permanent loops 46 in
screen 18.
[0025] Screen 18 may be made of a number of materials suitable for
projection screen applications. Preferably, screen 18 has a
reflectivity gain from about 0.4 to about 2.5. Front projections
screens are preferably white or light gray in appearance. Rear
projection screens are preferably light gray in color and
translucent to permit the projected image to transmit through the
screen and be displayed to the audience. Some of the screens are
acoustically transparent, like speaker cover fabric, to permit
sound to be transmitted through the screen.
[0026] According to one embodiment, the screen includes a woven
fiberglass backing with a vinyl reflective surface laminated to the
fiberglass (gain of approximately 1.0). According to one
embodiment, microscopic glass beads are provided on the viewing
surface (gain from about 0.5 to about 2.5 depending on the viewing
angle). According to another embodiment, the screen is made of a
white (gain of about 1.0 or from about 0.4 to about 2.2 depending
on the viewing angle) or light gray (gain of about 0.6 to 0.9
depending on the viewing angle) vinyl material without a backing.
Other suitable projection screens known to those of ordinary skill
in the art may also be provided. Preferably the screen is
substantially blank so that it is substantially free of printing or
other markings that noticeably detract from the images projected on
the screen. According to one embodiment, the substantially blank
screen is provided with black borders that frame the screen for
"wide screen" or other projection formats.
[0027] Couplers 20 are made of extruded, rigid PVC and include a
first end 48 having an interactive member 50 and a second end 52
having an open channel 54 sized to receive loops 46 of screen 18.
Preferably at the site of installation, each loop 46 is positioned
to extend down an open channel 54 of a respective coupler 20. A
retention rod 56 that is slightly longer than coupler 20 is slid
through an open end of each loop 46. This prevents the withdrawal
of the respective loop 46 from the respective screen coupler 20 to
couple each screen coupler 20 to an edge 44 of screen 18.
Preferably, retention rods 56 are hollow and made of HDPE plastic.
Because loops 46 are permanent, the position of couplers 20
relative to screen 18 is fixed by the manufacturer and not
dependent upon the skill of the installer.
[0028] After screen couplers 20 are coupled to screen 18, they are
coupled to frame 16 to tension screen 18 on frame 16. Each
interactive member 50 of couplers 20 includes a rib 58 that defines
an undercut groove 60 with a body 62 of coupler 20. Each frame
member 24 includes three spaced-apart interactive members 64, 66,
68 including ribs 70, 72, 74 that define undercut grooves 76, 78,
80. Interactive member 50 of screen coupler 20 mates with one of
interactive members 64, 66, 68 to couple coupler 20 to frame member
24. Each corner member 22 includes two sets of corresponding
interactive members 82, 84, 86 that align with respective
interactive members 64, 66, 68 of adjacent frame members 24 to
define continuous interactive members and grooves that extend
across junctions 88 defined between respective corner and frame
members 22, 24.
[0029] Each respective coupler 20, loop 46, and retention rod 56 is
longer than the distance between each exposed end of frame member
24 so that each coupler 20, loop 46, and rod 56 extends over the
respective junction 88 between corners 22 and frame members 24 when
couplers 20 are coupled to frame 16. Thus, continuous coupling is
provided along the entire length of frame members 24 and extends
over to corners 22.
[0030] After screen 18 is coupled to frame 16, frame 16 is mounted
to wall 14. As shown in FIGS. 3, 4, and 8, projection screen
apparatus 10 includes a pair of wall couplers 90 that are coupled
to wall 14 and frame 16 to support perimeter frame 16 on wall 14.
Wall coupler 90 is made of extruded aluminum and includes a first
flange 92 including a plurality of fastener-receiving apertures 94
and a second flange 96.
[0031] During installation, one or more wall couplers 90 are
coupled to wall 14 with second flange 96 extending upwardly.
Preferably, wall couplers 90 are positioned at the same level so
that perimeter frame 16 will be level and then fasteners 95, such
as screws, are inserted through apertures 94 into wall 14. Second
flange 96 and a flange 98 of frame members 24 defines channel 40
each have a ramped edge that facilitates insertion of flange 98
over second flange 96. As flange 98 of frame member 24 slides down
flange 96 of wall coupler 90, frame 16 is drawn closer to wall 14.
If necessary to center frame 16, frame 16 can be slid right or left
on wall couplers 90 to a centered position without having to remove
frame 16 from wall 14. To remove frame 16 for adjustment of the
tension in screen 18 or otherwise, frame 16 is raised up and
removed from wall 14.
[0032] FIGS. 7 and 8 illustrate screen 18 coupled to frame 16.
Preferably, frame member 24 has a width 100 that is 4 inches wide.
These figures and the others are proportional. Thus, one of
ordinary skill in the art can derive dimensions for the other
components from the figures based on the known width 100 of frame
24. According to alternative embodiments other widths are provided,
such as 2, 3, or 5 inches.
[0033] When coupled to frame 16, perimeter portions 110 of screen
18 overlap respective walk 112 of frame members 24 and
corresponding walk 114 of corner members 22. A substantially flat
display portion 116 of screen 18 is surrounded by perimeter
portions 110 and provides a display surface 118 on one side of
display portion 116 on which images projected on screen 18 by
projector 12 (either front or rear projection) are viewed by the
audience seated in front of projection screen apparatus 10. Display
surface 118 defines a plane 120 that has a first audience side 122
and an opposite second side 124. As shown in FIG. 8, screen coupler
20 is positioned on audience side 122 of plane 120 and wall coupler
90 is positioned on opposite side 124.
[0034] Wall 112 includes a first corner 126 on its inner edge that
causes screen 18 to turn or bend and divides screen 18 into
perimeter and display portions 110, 116 as shown in FIG. 8. Wall
112 also includes a second bend 128 that turns and divides
perimeter portion 110 of screen 18 into first and second segments
130, 132. Corner 126 and bend 128 assist in suppressing puckering
or creasing of screen caused by coupler 20 so that most, if not
all, puckering or creasing is removed from screen 18 before
reaching display portion 116 so that little or no distortion is
caused in display surface 118.
[0035] Second segment 132 of perimeter portion 110 defines a plane
134 having a first side 136 and a second side 138. When screen 18
is coupled to frame 16, interactive member 50 of coupler 20 is
positioned on first side 136 along with interactive members 64, 66,
68 of frame member 24 and interactive members 82, 84, 86 of corner
members 22.
[0036] As shown in FIG. 8, frame 16 includes a front side 140
facing the audience and an opposite back side 142. Front side 140
is preferably painted or otherwise colored black and includes a
face 144, an outer wall 146, and an inner side wall 148. When
screen 18 is coupled to frame 16, display portion 116 of screen 18
defines an angle 150 of 91.degree. to suppress images from
"washing" onto face 144. Furthermore, face 144 and inner side wall
148 have a relatively large radius of 0.25 inches therebetween that
further suppresses washing.
[0037] In a typical installation, frame 16 is first assembled as
described above. Screen 18 and screen couplers 20 are coupled
together as described above either before or after frame 16 is
assembled. Screen 18 is then coupled to frame 16 with screen
couplers 20. A tool 152, such as a plastic putty knife, is provided
to assist in coupling couplers 20 to frame 16. Each coupler 20
includes a rib 154 positioned opposite rib 58 that is configured to
receive a front edge 156 of tool 152.
[0038] Initially, screen coupler 20 is positioned adjacent to wall
112 of the respective frame member 24. By pressing on rib 154 with
tool 152, rib 58 is forced along wall 112 until it snaps into one
of grooves 76, 78, 80. When one end of rib 58 is positioned in
groove 76, tool 152 is slid along the length of coupler 20 forcing
the entire length of rib 58 into groove 76. Preferably, screen 18
is sized so that when ribs 58 of couplers 20 are positioned in
first grooves 76, screen 18 is properly tensioned so that display
portion 116 of screen 18 is properly tensioned and substantially
flat. Depending on factors, such as manufacturing tolerances,
temperature, or humidity, one or more of ribs 58 of couplers 20 may
need to be moved further outward to second or third grooves 78, 80
to obtain the proper tension.
[0039] After a period time passes from the initial installation,
screen 18 may stretch and develop a sag that noticeably distorts
the quality of the images displayed on screen 18. To remove this
sag, one or more couplers 20 is moved further out to the next
respective groove 78, 80 until the sag in screen 18 is removed.
Because couplers 20 an inaccessible from the front of projection
screen apparatus 10, it must first be removed from wall 14 before
the adjustment can be made.
[0040] As shown in FIG. 10, channel 26 is sized to receive coupler
26 and rod 56. Before shipping, coupler 26 and rod 56 are placed in
channel 26. This help avoids damage to coupler 26 and rod 56 during
shipping and also reduces the shipping space required.
[0041] Preferably, instructions for the assembly, installation,
and/or use of projection screen apparatus 10 are provided with
projection screen apparatus 10 or otherwise communicated to permit
a person or machine to assemble, install and/or use projection
screen apparatus 10. Such instructions may include a description of
any or all portions of projection screen apparatus 10 and/or any or
all of the above-described assembly, installation, and use of
projection screen apparatus 10 or components of projection screen
apparatus 10. The instructions may be provided on separate papers
and/or on the packaging in which projection screen apparatus 10 is
sold or shipped. These instructions may also be provided over the
Internet or other communication system. Furthermore, the
instructions may be embodied as text, pictures, audio, video, or
any other medium or method of communicating instructions known to
those of ordinary skill in the art.
[0042] Although the present invention has been described in detail
with reference to preferred embodiments, variations and
modifications exist within the scope and spirit of the present
invention as described and defined in the following claims.
* * * * *