U.S. patent application number 15/958424 was filed with the patent office on 2018-08-23 for tensioned projection screen assembly.
The applicant listed for this patent is Draper, Inc.. Invention is credited to Kenneth M. Risher.
Application Number | 20180239234 15/958424 |
Document ID | / |
Family ID | 43309263 |
Filed Date | 2018-08-23 |
United States Patent
Application |
20180239234 |
Kind Code |
A1 |
Risher; Kenneth M. |
August 23, 2018 |
TENSIONED PROJECTION SCREEN ASSEMBLY
Abstract
A projection screen assembly is disclosed including a projection
screen and a projection screen frame. The projection screen frame
includes a plurality of projection screen frame modules that may be
coupled together to provide a projection frame for projection
screens of different sizes.
Inventors: |
Risher; Kenneth M.;
(Indianapolis, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Draper, Inc. |
Spiceland |
IN |
US |
|
|
Family ID: |
43309263 |
Appl. No.: |
15/958424 |
Filed: |
April 20, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15385252 |
Dec 20, 2016 |
10018901 |
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15958424 |
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14731061 |
Jun 4, 2015 |
9551920 |
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15385252 |
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13377755 |
Apr 30, 2012 |
9110362 |
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PCT/US2010/038559 |
Jun 14, 2010 |
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14731061 |
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61186796 |
Jun 12, 2009 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
Y10T 29/49826 20150115;
G03B 21/58 20130101; G03B 21/62 20130101; F16M 11/04 20130101; G03B
21/56 20130101; G03B 21/60 20130101; G03B 21/625 20130101; G03B
21/10 20130101; Y10T 29/49947 20150115 |
International
Class: |
G03B 21/56 20060101
G03B021/56; F16M 11/04 20060101 F16M011/04 |
Claims
1. A projection screen apparatus including a projection screen
including a first sheet defining a perimeter of the projection
screen, at least one second sheet coupled to the first sheet, and a
bungee received in the at least one second sheet, and a projection
screen frame supporting the projection screen, the at least one
bungee coupling the projection screen to the projection screen
frame.
2. The projection screen apparatus of claim 1, wherein the second
sheet includes a tube receiving the bungee.
3. The projection screen apparatus of claim 1, wherein the second
sheet includes an aperture receiving a terminal end of the
bungee.
4. The projection screen apparatus of claim 1, wherein the second
sheet decreases in stiffness from an outer end to an inner end.
5. The projection screen apparatus of claim 1, wherein the bungee
includes a pair of terminal ends received in the second sheet.
Description
RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent
application Ser. No. 15/385,252, filed Dec. 20, 2016, titled
TENSIONED PROJECTION SCREEN ASSEMBLY, which is a divisional
application of U.S. patent application Ser. No. 14/731,061, filed
Jun. 4, 2015, now U.S. Pat. No. 9,551,920, titled TENSIONED
PROJECTION SCREEN ASSEMBLY, which is a divisional application of
U.S. Pat. application Ser. No. 13/377,755, filed Apr. 30, 2012, now
U.S. Pat. No. 9,110,362, titled TENSIONED PROJECTION SCREEN
ASSEMBLY, which is a nationalization under 37 U.S.C. .sctn. 371 of
International Application No. PCT/US2010/038559 to Risher, filed
Jun. 14, 2010, titled TENSIONED PROJECTION SCREEN ASSEMBLY, which
claims the priority benefit of U.S. Provisional Patent Application
Ser. No. 61/186,796 to Risher, filed Jun. 12, 2009, titled
"Tensioned Projection Screen," the entire disclosures of which are
expressly incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present disclosure relates a projection screen assembly,
more particularly, a projection screen assembly having a screen
held by tension on a frame.
BACKGROUND OF THE INVENTION
[0003] Projection screen assemblies are provided to display images,
typically projected from a source, such as a projector. The images
often depict movies or other forms of entertainment, but can also
depict other images, such as advertising.
[0004] According to one aspect of the present disclosure, a
projection screen kit is provided including a plurality of
projection screens including a first projection screen having a
first viewing area adapted to display an image projected onto the
first projection screen and a second projection screen having a
second viewing area adapted to display an image projected onto the
second projection screen. The kit further includes a plurality of
frame modules adapted to be assembled to define an assembled frame
for each of the plurality of the plurality of projection screens.
Each assembled frame is sized to support at least one of the
plurality of projection screens. Each assembled frame for the
plurality of projection screens requires a number of frame modules
to support at least one of the plurality of projection screens. The
total number of frame modules in the kit is less than the sum of
the frame modules required to assemble all of the plurality of
assembled frames at one time.
[0005] According to another aspect of the present disclosure
projection screen apparatus is provided including a projection
screen including a viewing surface adapted to display an image
projected onto the projection screen and a plurality of connectors,
and a projection screen frame having an outward facing perimeter
surface and a plurality of connectors coupled to the outward facing
perimeter surface. The plurality of connectors of the projection
screen connect with the plurality of connectors of the projection
screen frame to connect the projection screen to the projection
screen frame.
[0006] According to another aspect of the present disclosure, a
projection screen apparatus is provided that includes a projection
screen including a viewing surface adapted to display an image
projected onto the projection screen and a plurality of connectors,
and a projection screen frame supporting the projection screen. The
projection screen includes a plurality of frame modules. Adjacent
frame modules are coupled together to define a joint therebetween.
Each frame module has a first end and a second end positioned
clockwise of the first end. The projection screen frame further
includes a plurality of connectors including a first connector
coupled to each frame module adjacent to the first end of each
frame module and a second connector coupled to each frame module
adjacent the second end of each frame module. All of the first
connectors are positioned the same distance from the first ends of
the frame module to which it is coupled. All of the second
connectors are positioned the same distance from the second ends of
the frame module to which it is coupled.
[0007] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a projection
screen including a viewing surface adapted to display an image
projected onto the projection screen and a plurality of bungee
connectors extending from a perimeter of the projection screen, and
a projection screen frame supporting the projection screen. The
bungee connectors extend to the projection screen frame.
[0008] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a projection
screen including a viewing surface adapted to display an image
projected onto the projection screen and a plurality of loop
connectors extending from a perimeter of the projection screen, and
a projection screen frame including a plurality of posts. The loop
connectors of the projection screen extend around the plurality of
posts to support the projection screen.
[0009] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a projection
screen including a viewing surface adapted to display an image
projected onto the projection screen and a plurality of bungee
connectors. Each bungee connector has at least one terminal end.
The projection screen further includes a projection screen frame
supporting the projection screen. The bungee connectors extend to
the projection screen frame.
[0010] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a projection
screen including a viewing surface adapted to display an image
projected onto the projection screen and a plurality of bungee
connectors permanently coupled to the projection screen, and a
projection screen frame supporting the projection screen. The
bungee connectors coupling the projection screen to the projection
screen frame.
[0011] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a projection
screen including a first sheet defining a perimeter of the
projection screen, at least one molded plastic sheet coupled to the
first sheet, and at least one connector coupled to the at least one
molded plastic sheet, and a projection screen frame supporting the
projection screen. The at least one connector couples the
projection screen to the projection screen frame.
[0012] According to another aspect of the present disclosure, a
projection screen apparatus including a projection screen including
a first sheet defining a perimeter of the projection screen and at
least one second sheet coupled to the first sheet. The second sheet
having a stiffness that increases from an inner end to an outer
end. The projection screen further includes at least one connector
coupled to the at least one second sheet. The projection screen
apparatus further includes a projection screen frame supporting the
projection screen. The at least one connector couples the
projection screen to the projection screen frame.
[0013] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a projection
screen including a first sheet defining a perimeter of the
projection screen, at least one second sheet coupled to the first
sheet, and a bungee received in the at least one second sheet, and
a projection screen frame supporting the projection screen. The at
least one bungee couples the projection screen to the projection
screen frame.
[0014] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a projection
screen includes a first sheet defining a perimeter of the
projection screen, at least one tube, and a cord received in the
tube, and a projection screen frame supporting the projection
screen. The at least one cord couples the projection screen to the
projection screen frame.
[0015] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a projection
screen including a viewing surface adapted to display an image
projected onto the projection screen and a plurality of connectors,
and a projection screen frame supporting the projection screen. The
projection screen frame includes a plurality of posts. The
plurality of connectors connect to the plurality of posts to couple
the projection screen to the projection screen frame.
[0016] According to another aspect of the present disclosure, a
projection screen apparatus is provided including at least one
projection screen including a viewing surface adapted to display an
image projected onto the projection screen and a plurality of
connectors, an accessory having at least one connector, and a
projection screen frame supporting the projection screen. The
projection screen frame includes a plurality of connectors. The
plurality of connectors of the projection screen connect to the
plurality of connectors of the projection screen frame to couple
the projection screen to the projection screen frame. At least one
of the plurality of connectors of the projection screen frame
connects to at least one connector of the at least one projection
screen at least one connector of the accessory.
[0017] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a first
projection screen including a viewing surface adapted to display an
image projected onto the first projection screen, a second
projection screen including a viewing surface adapted to display an
image projected onto the second projection screen, and a projection
screen frame supporting the first and second projection screens
with the viewing surface of the first projection screen facing away
from the viewing surface of the second projection screen.
[0018] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a projection
screen including a viewing surface adapted to display an image
projected onto the projection screen and a plurality of connectors
spaced apart by a uniform distance, and a projection screen frame
supporting the projection screen. The projection screen includes a
plurality of frame modules. Each frame module has a length that is
a multiple of the uniform distance.
[0019] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a projection
screen having a height, a width and a thickness, and a projection
screen frame supporting the projection screen. The height of the
projection screen is greater than a height of the height of the
projection screen frame by more than the thickness of the
projection screen.
[0020] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a projection
screen adapted to display an image projected onto the projection
screen, a projection screen frame supporting the projection screen,
at least one leg supporting the projection screen frame on the
ground, and at least one connector coupling the at least one leg to
the projection screen frame. At least one of an outer surface of
the leg and a surface of the connector define a junction including
a groove and a tooth received in the groove.
[0021] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a projection
screen adapted to display an image projected onto the projection
screen, a projection screen frame supporting the projection screen,
at least one leg supporting the projection screen frame on the
ground, and at least one connector coupling the at least one leg to
the projection screen frame. The connector wraps around at least a
portion of the at least one leg.
[0022] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a projection
screen adapted to display an image projected onto the projection
screen, a projection screen frame supporting the projection screen,
at least one leg supporting the projection screen frame on the
ground, and at least one connector having base and a pair of arms.
The base receives a portion of at least one of the projection
screen frame and the leg and the pair of arms cooperate to receive
the other of the projection screen frame and the leg between the
arms.
[0023] According to another aspect of the present disclosure, a
projection screen apparatus is provided that includes a projection
screen adapted to display an image projected onto the projection
screen and a plurality of connectors and a projection screen frame
supporting the projection screen. The projection screen includes a
plurality of connectors coupling to the plurality of connectors of
the projection screen. The projection screen apparatus further
includes at least one drape and at least one drape support
connected to at least one of the plurality of connecters of the
projection screen frame and support the drape.
[0024] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a projection
screen adapted to display an image projected onto the projection
screen and a projection screen frame supporting the projection
screen. The projection screen frame includes a plurality of frame
modules having longitudinal axes. Adjacent frame modules cooperate
to define a joint therebetween. The projection screen apparatus
further includes at least one frame coupler coupling together
adjacent frame modules cooperating to define a joint. The at least
one coupler pulls the adjacent frame modules axially toward each
other.
[0025] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a projection
screen adapted to display an image projected onto the projection
screen and a projection screen frame supporting the projection
screen. The projection screen frame including a plurality of frame
modules including first and second adjacent frame modules
cooperating to define a joint therebetween. The first adjacent
frame module includes a slot. The projection screen apparatus
further includes at least one frame coupler coupling together
adjacent frame modules that cooperate to define a joint. The at
least one frame coupler including a plate positioned in the slot
and a threaded member coupled to the second adjacent frame module
and positioned in a threaded aperture of the plate.
[0026] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a projection
screen adapted to display an image projected onto the projection
screen, and a projection screen frame supporting the projection
screen. The projection screen including a plurality of frame
modules including first and second adjacent frame modules coupled
together and cooperating to define a joint therebetween. The first
and second adjacent frame modules have longitudinal axes. The first
adjacent frame module includes an axially extending protrusion
having a surface defining an acute angle with the axis of the first
adjacent frame module. The second adjacent frame module includes a
recess receiving the axially extending protrusion of the first
adjacent frame module. The recess is defined by a surface that
contacts the surface of the axially extending protrusion.
[0027] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a projection
screen adapted to display an image projected onto the projection
screen. The projection screen has a top portion, bottom portion,
and side portions extending between the top and bottom portions.
The projection screen apparatus further includes a projection
screen frame supporting the projection screen in a vertical
position. The projection screen frame has a top portion positioned
adjacent to the top portion of the projection screen, a bottom
portion positioned adjacent to the bottom portion of the projection
screen, and side portions extending between the top portion and the
bottom portion of the projection screen. The side portions of the
projection screen frame are positioned adjacent to the side
portions of the projection screen. The top portion of the
projection screen frame has resilient feet.
[0028] According to another aspect of thee the present disclosure,
a projection screen apparatus is provided including a projection
screen adapted to display an image projected onto the projection
screen, a projection screen frame supporting the projection screen,
and at least one leg supporting the projection screen frame on the
ground. The at least one leg having a plurality of frame modules
including a horizontal member and a vertical member that is
interchangeable with the horizontal member.
[0029] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a projection
screen adapted to display an image projected onto the projection
screen and a projection screen frame supporting the projection
screen. The projection screen includes a plurality of frame modules
including first and second adjacent frame modules coupled together
by a coupler and cooperating to define a joint therebetween. The
projection screen apparatus further includes a stiffener extending
across the joint to further couple the first and second adjacent
members together.
[0030] According to another aspect of the present disclosure, a
projection screen apparatus is provided including a projection
screen adapted to display an image projected onto the projection
screen, a projection screen frame including a plurality of frame
modules supporting the projection screen, and at least one leg
including a plurality of frame modules supporting the projection
screen frame on the ground. At least one of the frame modules of
the at least one leg is interchangeable with the plurality of frame
modules of the projection screen frame.
[0031] According to another aspect of the present disclosure, a
method of constructing a projection screen apparatus is provided.
The method includes the steps of receiving at least one
pre-manufactured projection screen and a plurality of
pre-manufactured frame modules, selecting a subset of the plurality
of pre-manufactured frame modules sufficient to construct a
projection screen frame corresponding to the at least one
pre-manufactured projection screen, constructing the projection
screen frame using the subset of the plurality of pre-manufactured
frame modules, and coupling the pre-manufactured projection screen
to the projection screen frame.
[0032] According to another aspect of the present disclosure, a
method of facilitating constructing a projection screen apparatus
is provided. The method includes the steps of receiving a
projection screen and a plurality of pre-manufactured frame
modules, selecting a subset of the plurality of pre-manufactured
frame modules sufficient to construct a projection screen frame
corresponding to the at least one pre-manufactured projection
screen, providing the subset of the plurality of pre-manufactured
frame modules to another party, and providing instructions on the
construction of the projection screen frame from the
pre-manufactured frame modules to the party.
[0033] According to another aspect of the present disclosure, a
method of facilitating construction of a projection screen
apparatus is provided. The method includes the steps of providing a
projection screen requiring a projection screen frame of a
predetermined size to support the projection screen during use,
providing a plurality of frame modules greater than the number of
projection frame modules necessary to construct the projection
screen frame, sending the projection screen to another party, and
sending the plurality of frame modules to the party for use in
constructing the projection screen frame to support the projection
screen during use.
[0034] According to another aspect of the present disclosure, a
method of facilitating construction of a projection screen
apparatus is provided including the steps of collecting a plurality
of projection screens requiring a plurality of projection screen
frames of a predetermined size to support the plurality of
projection screens during use, collecting a plurality of projection
screen frame modules less than the number of projection screen
frame modules necessary to construct the plurality of projection
screen frames at one time, providing the plurality of projection
screens to another party, and providing the plurality of frame
modules to the party for use in constructing at least one of the
plurality of projection screen frames.
[0035] According to another aspect of the present disclosure, a
method of constructing a projection screen apparatus is provided.
The method includes the steps of providing a projection screen and
a plurality of frame modules, the plurality of frame modules
including at least two identical frame modules, constructing a
projection screen frame with the plurality of frame modules
including at least one identical frame module, supporting the
projection screen with the projection screen frame, constructing at
least one leg with the plurality of frame modules including at
least one identical frame module, and supporting the projection
screen frame with the at least one leg.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] The above-mentioned and other features of the present
disclosure will become more apparent and will be better understood
by reference to the following description of embodiments of the
present disclosure taken in conjunction with the accompanying
drawings, wherein:
[0037] FIG. 1 is a diagrammatic view of a projection screen
assembly showing the assembly including a pair of legs, a frame
supported by the pair of legs, and a screen supported by the frame
to display an image projected by a projector;
[0038] FIG. 2 is a view of a diagram showing a corner module and a
plurality of frame modules and four frames assembled using various
combinations of the corner modules and frame modules to create
different sizes and formats of frames;
[0039] FIG. 3 is a side elevation view of a frame of the projection
screen assembly of FIG. 1 showing four corner modules and four
frame modules assembled to create a frame;
[0040] FIG. 4 is a perspective view of a corner module of FIG. 3
and two frame modules coupled to the corner module;
[0041] FIG. 5 is a view similar to FIG. 4 showing the two frame
modules aligned with the corner module for coupling thereto;
[0042] FIG. 6 is a perspective view of the corner module of FIG.
4;
[0043] FIG. 7 is a cross-sectional view of the corner module of
FIG. 4 taken along line 7-7 of FIG. 6;
[0044] FIG. 8 is an assembly view of the corner module of FIG.
4;
[0045] FIG. 9 is a perspective view of a frame module of FIG.
4;
[0046] FIG. 10 is an assembly view of the frame module of FIG.
9;
[0047] FIG. 11 is a side elevation view of a leg of the projection
screen assembly showing the leg including a T-shaped base module
and a three frame modules coupled to the T-shaped base module;
[0048] FIG. 12 is a perspective view of the T-shaped base
module;
[0049] FIG. 13 is a perspective view of a portion of the leg of
FIG. 11 and the frame of FIG. 3 showing the frame coupled to the
leg with a clamp and a portion of the screen positioned over the
clamp;
[0050] FIG. 14 is a view similar to FIG. 13 with the frame removed
for clarity;
[0051] FIG. 15 is a perspective view of the clamp of FIG. 13;
[0052] FIG. 16A is a cross-sectional view taken along line 16-16 of
FIG. 13;
[0053] FIG. 16B is an enlarged view of a portion of FIG. 16A;
[0054] FIG. 17 is a perspective view of the frame and screen
showing the screen coupled to the frame with a pair of studs and
elastic loops;
[0055] FIG. 18 is a side elevation view of the screen and three
elastic loops coupled to the screen with three stitch patterns;
[0056] FIG. 19 is a cross-sectional view taken along line 19-19 of
FIG. 18;
[0057] FIG. 20 is view similar to FIG. 1 showing the frame having a
pair of--T-shaped base modules replacing the upper corner modules
of the frame, another pair of T-shaped base modules coupled to the
previously mentioned T-shaped base modules, frame modules coupled
to the later-mentioned T-shaped base modules, and a drape (shown in
phantom) supported by the frame to border the screen also supported
by the frame;
[0058] FIG. 21 is a perspective view of a pair of frame modules
coupled end-to-end to form a joint therebetween and a third frame
module coupled to the pair of frame modules to span and stiffen the
joint;
[0059] FIG. 22 is a perspective view of an projection screen kit
including a container, multiple screens and frame components, and a
frame diagram provided on the container;
[0060] FIG. 23 is a perspective view similar to FIG. 21 showing a
pair of bars coupled to the pair of frame modules to span and
stiffen the joint;
[0061] FIG. 24 is a perspective view showing a plate and elastic
cord provided to couple the screen to the studs mounted on the
frame;
[0062] FIG. 25 is a perspective view showing a plate and elastic
cord provided to couple the screen to the studs mounted on the
frame;
[0063] FIG. 26 is a perspective view of another clamp;
[0064] FIG. 27 is a top plan view of the clamp of FIG. 26
positioned adjacent to a frame member with arms of the clamp in an
open position;
[0065] FIG. 28 is a view similar to FIG. 27 showing the arms
swinging toward a closed position as the clamp is pushed over the
frame member;
[0066] FIG. 29 is a perspective view of an the opposite ends of an
alternative embodiment frame module;
[0067] FIG. 30 is a cross-sectional view of an alternative
embodiment loop connecting plate;
[0068] FIG. 31 is a perspective view of a drape support;
[0069] FIG. 32 is a cross-sectional view of the drape support of
FIG. 31;
[0070] FIG. 33 is a side elevation view of the drape support of
FIG. 31;
[0071] FIG. 34 is a cross-sectional view showing a pair of loops
coupled to a single post;
[0072] FIG. 35 is a perspective view of showing a pair of
alternative embodiment drape supports;
[0073] FIG. 36 is an end view showing a bottom of a upside down
U-shaped drape support of FIG. 35; and
[0074] FIG. 37 is a side elevation view of a portion of an
alternative embodiment drape support of FIG. 35 coupled to a post
of the projection screen frame.
[0075] Corresponding reference characters indicate corresponding
parts throughout the several views. Although the drawings represent
embodiments of the present invention, the drawings are not
necessarily to scale and certain features may be exaggerated in
order to better illustrate and explain the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION
[0076] The embodiments disclosed below are not intended to be
exhaustive or limit the invention to the precise forms disclosed in
the following detailed description. Rather, the embodiments are
chosen and described so that others skilled in the art may utilize
their teachings.
[0077] 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 includes a pair of
legs 14 to support itself on a floor of a structure. According to
alternative embodiments of the present disclosure, projection
screen apparatus 10 may be suspended on a wall, ceiling, or other
structure using fasteners, cables, or other suitable devices.
[0078] 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.
[0079] As shown in FIG. 1, projection screen apparatus 10 further
includes a perimeter, projection screen frame 16 and a projection
screen 18 tensioned on frame 16. Exemplary Frame 16 includes four
corner frame modules 22 and four extended frame members 24
extending between corner modules 22 as shown in FIG. 3. Each frame
member 24 is made of one or more frame modules 26. The length and
number of frame modules 26 for each frame members 24 depends upon
the size of screen 18 used in a particular application, such as a
tradeshow.
[0080] As shown in FIG. 2, frame modules 26 are provided in various
sizes including modules 26A, 26B, 26C, 26D, 26E, and 26F. Other
sizes and lengths of modules 26 may also be provided. Also shown
diagrammatically in FIG. 2 are several frames 16 assembled using
different sizes and numbers of frame modules 26 and various screens
18 (shown from the rear) supported by frames 16. Each frame 16 has
a different height and width depending on which modules 26 were
used. As an example, the below tables illustrates various
combinations of frame modules 26 used to create different size
frames 16A-16D shown in FIG. 2.
TABLE-US-00001 module Frame 26A 26B 26C 26D 26E 26F 22 Screen 16A
-- -- -- 6 2 2 4 18A 16B 2 -- 2 2 4 2 4 18B 16C -- -- -- 2 10 -- 4
18C 16D -- -- -- 4 4 6 4 18D Kit 2 -- 2 4 10 6 4 18A, 18B, 242 min.
18C, and 18D Kit 3 3 5 11 7 5 18A, 18B, 242 min. +1 18C, and
18D
[0081] Different combinations of frame modules 26 can be used to
assemble taller/shorter and/or wider/narrower frames 16. For
example in frame 16B, frame module 26B could replace frame module
26A to create a wider frame. As shown in the above table, a
corresponding screen 18A, 18B, 18C, 18D is provided with each frame
16A, 16B, 16C, 16D. Similarly, if different modules 26 are provided
to create different frame sizes, different sizes of screen 18 may
be provided to correspond to the differently sized frame 16.
[0082] Frame 16 is shown in FIG. 3 to include four corner modules
22 and four frame members 24 each including a single module 26 for
simplicity of explanation. Normally, each frame member 24 will
include multiple modules 26 as shown diagrammatically in FIG. 2.
Each corner module 22 and each frame module 26 includes male
portion 28 and female portion 30 as shown in FIG. 5. Each male
portion 28 is configured to couple to a respective female portion
30. For example as shown in FIG. 5, male portion 28 of corner
module 22 is configured to couple to a female portion 30 of an
adjacent frame module 26 and female portion 30 of corner module 22
is configured to couple to a male portion 28 of an adjacent frame
module 26. Similarly, male portion 28 of frame module 26 is
configured to couple to a female portion 30 of an adjacent corner
module 22 (or frame module 26) and female portion 30 of frame
module 26 is configured to couple to a male portion 28 of an
adjacent corner module 22 (or frame module 26).
[0083] Each male portion 28 includes a threaded assembly or coupler
32 that threads into or is coupled to a nut or coupler 34 of female
portion 30. Once coupled together by couplers 32, 34, corner
modules 22 and frame modules 26 create substantially rigid frame 16
as shown in FIGS. 3 and 4.
[0084] As shown in FIGS. 5-8, each corner module 22 includes a pair
of outer perimeter tubes 36, inner perimeter tube 38, and inner
perimeter tube segments 40 that cooperate to define segmented,
inner perimeter tube 42, all of which are welded together to form
tubular frame 44. Corner module 22 further includes a cast, corner
46 that is inserted into respective outer perimeter tubes 36,
preferably before welding.
[0085] Each male portion 28 includes a pair of inserts 48 sized to
fit within the ends of respective tubes 36, 38 and a pair of posts
50 received in inserts 48. Inserts 48 are preferably molded of
plastic and posts 50 are preferably steel and over-molded into
inserts 48 during the molding process. As shown in FIG. 7, each
post 50 includes a shoulder 52 that prevents withdrawal of posts 50
from respective inserts 48. Each insert 48 includes a raised
shoulder or rim 54 that mates with female portion 30 as discussed
below.
[0086] Each male portion 28 further includes a pair of split
collars or plates 56 fastened to tubes 36, 38 with fasteners 58
that extend through tubes 36, 38 into inserts 48. Collars 56 wrap
around tubes 36, 38 to provide a relatively flat profile. Collars
56 further include channel 60 and groove 62 that receive coupler 32
as shown in FIGS. 7 and 8.
[0087] Coupler 32 includes a threaded post or bolt 64 having a
threaded shank 66, knob 68, and hex head 70. Coupler 32 further
includes clip 72 that fits within groove 74 in shank 66 and collar
76. Clip 72 is received in groove 62 and prevents shank 66 from
translating up or down collars 56 during rotation of shank 66 as
described below. Collar 76 receives shank 66 and distributes the
load applied by threaded post 64 during coupling of coupler 32 of
male portion 28 with coupler 34 of female portion 30 as described
below.
[0088] Each female portion 30 includes a pair of inserts 78 sized
to fit within the ends of respective tubes 36, 42 and defining a
pair of apertures 80 sized to receive posts 50 of male portions 28.
Inserts 78 are preferably molded of plastic and includes an annular
channel 82 that mates shoulder 52 of inserts 48 of male portions
28.
[0089] Each female portion 30 further includes a pair of split
collars or plates 84 fastened to tubes 36, 42 with fasteners 58
that extend through tubes 36, 42 into inserts 78. Collars 84 wrap
around tubes 36, 42 to provide a relatively flat profile. Collars
84 further include channel 86 and groove 88 that receive coupler 32
as shown in FIGS. 7 and 8.
[0090] Coupler 34 includes plate 90 having a threaded aperture 92
that receives threaded shank 66 of post 64 of coupler 32. Plate 90
is positioned in groove 88 and receives shank 66 and distributes
the load applied by threaded post 64 during coupling of coupler 32
of male portion 28 with coupler 34 of female portion 30.
[0091] An alternative embodiment coupler 34' is shown in FIG. 29.
Coupler 34 is similar to coupler 34, but includes two bolts 64.
Plate 90' includes a pair of threaded apertures 92 that receive
threaded shanks 66 of bolts 64.
[0092] Similar to corner module 22, frame modules 26 each include
tubes 94. Frame modules 26 further includes inserts 48, 78 inserted
within tubes 94 and collars 56, 84 supporting couplers 32, 34. In
addition to supporting respective couplers 32, 34, collars 56, 84
also support tubes 94 at a predetermined position. Each module 26
further includes a middle pair of collars or plates 96 that support
tubes 94 at the predetermined position.
[0093] During assembly of frame 16, posts 50 of male portions 28
are aligned with apertures 80 of female portions 30 and inserted
therein. With this alignment, threaded shank 66 of coupler 32 is
aligned with threaded aperture 92 in plate 90 of coupler 34. An
assembler turns post 64 by rotating knob 68 by hand or otherwise or
uses a tool on hex head 70. As post 64 turns, shank 66 is drawn
further into plate 90, which draws male and female portions 28, 30
together until they are firmly locked as show in FIG. 4.
[0094] In addition to forming portions of frame 16, frame modules
26 may also be used to form portions of legs 14 as shown in FIGS. 1
and 11. Legs 14 include a base module 98 and one or more frame
modules 26. Each base module 98 includes a plurality of tubes 100,
102 and tube segments 104, 106 that cooperate to define a segmented
tube 108. Tubes 100, 102, 108 are welded together to form tubular
frame 109. Base module 98 includes male coupler 32 and a pair of
female couplers 34. As shown in FIGS. 1 and 11, one or more frame
modules 26 are coupled to base module 98 at female couplers 34 to
form horizontal base 110 of legs 14 and one or more frame modules
26 are coupled to base module 98 at male couplers 32 to form
vertical uprights 112 of legs 14.
[0095] Base modules 98 may also replace corner modules 22 to create
a frame 16 that supports drape 99. Drape 99 has an opening that
allows screen 18 to be seen by an audience, but otherwise covers
border 182 of screen 18 and most of frame 16. Additional base
modules 98 are coupled to the base modules 98 that replaced upper
corner modules 22. Frame modules 26 are coupled to these upper-most
base modules 98 to create a cross bar 101 to support drape 99.
Stiffening bars 218, 219, discussed below, can be used to couple
frame modules between the upper-most base modules 98 that have a
female-to-female joint 221 there-between.
[0096] Frame 16 is coupled to uprights 112 of legs 14 as shown in
FIG. 13 by one or more clamps or connectors 114 and hook 115.
Clamps 114 are preferably provided at a lower portion of frame 16,
as shown in FIG. 13, and upper portion of frame 16. Clamps 114 wrap
around either tubes 36 of corner modules 22, as shown in FIG. 13,
or tubes 94 of frame modules 26 to couple frame 16 to uprights 112.
Optional hook 115 supports post 162 on frame 16.
[0097] As shown in FIG. 16A, clamp 114 includes a U-shaped base
116, and a pair of L-shaped arms 118 pivotally attached to base 116
by a pair of hinge pins 120. Clamp 114 further includes drive 122
having threaded post, bolt, or compresion members 124 having a
threaded shank 126, knob 128, and hex head 130 and rubber bumper
132 coupled to an end of threaded shank 126.
[0098] During coupling of frame 16 to legs 14, L-shaped arms 118
wrap around tube 36 of corner module 22 (or tube 94 of frame module
26) and U-shaped base 116 receives tube 94 of frame module 26. The
assembler rotates knob 128 so threaded shank 126 feds through
threaded aperture 134 of base 116, which drives rubber bumper 132
into tube 94 and draws L-shaped arms 118 into tube 36, causing tube
36 of corner module 22 to be drawn or compressed together with tube
94 of frame module 26.
[0099] Rubber pad or resilient feet 136 are provided on one or more
sides of tubes 94 of frame modules 26. As tube 36 of corner module
22 is drawn together with tube 94 of frame modules 26, rubber feet
136 are compressed to create grip between tubes 36, 94. As shown in
FIG. 11, rubber feet 136 also support legs 14 on the floor or
ground to provide clearance for collars 56, 84. When not used on
legs 14, feet 136 of side frame modules used to construct
projection screen frame 16 are spaced apart from the ground and are
coupled to an inward facing surface of projection screen frame 16.
Similarly, when not used on frame members 24 for projection screen
frame 16, posts 162, which form projection screen frame connectors,
are spaced apart from connectors of projection screen 18, such as
loops 164.
[0100] When leg 14 is coupled to projection screen frame 14,
identical frame members, such as frame modules 26, may be oriented
in different planes. For example, a frame module 26 used to
construct projection screen frame 16 may be substantially
horizontal or vertical and parallel to screen 18 and an identical
frame module 26 may be normal to screen 18.
[0101] As shown in FIG. 16B, tubes 36, 94 and the other tubes,
described herein, include a plurality of longitudinally extending
grooves or recesses 138 formed in an exterior surface of projection
screen frame 16 and L-shaped arms 118 include teeth 140 sized to
fit within grooves 138. As L-shaped arms 118 are drawn toward tube
36 by drive 122, teeth 140 are positioned further in grooves 138.
Teeth 140 resist L-shaped arms 118 from being pulled away from
tubes 36 when drive 122 is compressing tubes 36, 94 together.
[0102] Alternative embodiment clamp 142 is shown in FIGS. 26-28.
Clamp 142 is similar to clamp 114 discussed above, but includes
overlapping, L-shaped arms 144 that each have a pair of teeth 146
to fit into grooves 138 of tubes 36.
[0103] To clamp tube 36 to tube 94 as shown in FIG. 13, tubes 36,
94 are aligned as shown in FIG. 13. Next, respective clamps 114,
142 in an open position, as shown in FIG. 27, are positioned behind
tube 94. U-shaped base 116 is then inserted over tube 94 to a
position as shown in FIGS. 13 and 16 so that arms 118, 144 of
respective clamps 114, 142 wrap around tube 36.
[0104] During seating of clamps 114, 142 on tubes 36, 94,
respective arms 118, 144 swing from an open position as shown in
FIG. 27 for clamp 142, to an partially closed position as shown in
FIG. 28, and to a closed position as shown in FIG. 16 for clamp
114. This swinging results from placement of clamps 114, 142 over
tube 94.
[0105] As with clamp 114, clamp 142 includes collars 148 that
receive pins 120. Collars 148 have a substantially circular surface
150 with a center of curvature located at the center of pins 120.
Collars 148 further include a substantially flat surface 152 that
is positioned adjacent to tube 94 when clamps 114, 142 are fully
seated on tubes 94 as shown in FIG. 16 for clamp 114.
[0106] When arms 144 of clamp 142 are in the open position, as
shown in FIG. 27, circular surfaces 150 of collars 148 are
separated by distance 154 that is less than width 156 of tube 94,
which creates interference between collars 148 and tube 94 during
insertion of clamps 114, 142 over tube 94. This interference
creates frictional force between circular surfaces 150 of collars
148 and tube 94 in direction 158 that causes collars 148 and the
remainder of respective arms 118, 144 of clamps 114, 142 to rotate
in direction 160 as base 116 is slide over tube 94 to an
intermediate position, as shown in FIG. 28, and to a fully closed
position, as shown in FIGS. 13-16 for clamp 114 and FIG. 26 for
clamp 142. Eventually, arms 118, 144 of respective clamps 114, 142
are fully rotated so that flat surfaces 152 of collars 148 are
substantially parallel, which reduces or eliminates the
interference and resulting friction.
[0107] When tube 36 is aligned with tube 94, as shown in FIGS. 13
and 16, and clamp 114 (or clamp 142) is inserted over tube 94, arms
118 (or 144) automatically wrap around tube 36. As a result, arms
118, 144 of respective clamps 114, 142 are automatically positioned
around tube 36 so that drive 122 can be rotated to lock teeth 146
into grooves 138 of tube 36. To uncouple frame 16 from legs 14,
drives 122 of respective clamps 114, 142 are rotated in the
opposite direction and clamps 114, 142 are pulled off tubes 36,
94.
[0108] Typically before frame 16 is attached to legs 14, projection
screen 18 is secured to frame 16. According to the preferred
embodiment of the present disclosure, projection screen 18 is
coupled to frame 16 using a plurality of studs or post 162 on frame
16 and loops 164 on screen 18. As shown in FIG. 3, posts 162 are
provide on an outwardly facing perimeter surface 167 of frame 16.
Posts 162 may also be provided on other surfaces of frame 16. Posts
162 are a preferred connector of projection screen frame 16 that
connect with loops 164 to couple screen 18 to frame 16. According
to alternative embodiments of the present disclosure, other
connector may be provided, such as snaps, velcro, or other
connectors to couple screen 18 to frame 16.
[0109] Posts 162 are preferably coupled to outward facing perimeter
surface 167 of projection screen frame 16. However, posts 162 and
the other frame connectors disclosed herein may be coupled to other
surfaces of projection screen frame 16, such as the forward facing
surface, the inward facing surface, or the reward facing
surface.
[0110] As shown in FIG. 3, posts 162 are provided at equal
increments 161 around frame 16 after corner modules 22 and frame
modules 26 are assembled. Loops 164 are also provided at these
increments 161 on the outer perimeter of screen 18 as shown in FIG.
17. According to the preferred embodiment of the present
disclosure, posts 162 and loops 164 are provided at increments 161
of six inches.
[0111] To maintain the equal increments, posts 162 adjacent to ends
163, 165 of modules 26 and corner module 22 are positioned half the
increment length 161 from the respective ends 163, 165 as shown in
FIG. 4. For example, the preferred increment 161 is six inches. As
a result, the preferred spacing 159 of posts 162 adjacent to ends
163, 165 is three inches from respective ends 163, 165 so that
these adjacent posts 162 are six inches apart from each other.
[0112] Further, the length of modules 26 and corner modules 22 are
preferably multiplies of the preferred increment length. For
example, as stated above, the preferred increment length is six
inches and corner modules 22 and frame modules 26A, 26B, 26C, 26D,
26E, and 26F are 12, 24, 36, 42, 48, 60, and 72 inches in length,
respectively, each of which is a multiple of six inches. Put
another way, the preferred increment length (6 inches) is a factor
of each of the lengths of corner modules 22 and frame modules 26A,
26B, 26C, 26D, 26E, and 26F. As a result, the length of module 22,
26A, 26B, 26C, 26D, 26E, and 26F is a multiple of the spacing
between posts 162. The sum of the distance 159 between one post 162
to joint 222 (ex. three inches) and the distance 159 between the
other post 162 adjacent to that joint 222 to joint 222 (ex. three
inches) is equal to the incremental distance 161 between all posts
162 (ex. six inches). The preferred distance between posts 162
(adjacent to joint 222) and joint 222 is one-half the distance
between posts 162 (ex. 3 inches is one half of six inches).
According to alternative embodiments, the distance between the
posts 162 (adjacent to joint 222) and joint 222 are not equal. For
example, the distance between one stud to joint 222 is two inches
and the distance between the other post 162 and joint 222 is four
inches to create a six inch distance between posts 162. According
to alternative embodiments of the present disclosure, the spacing
of posts 162 are not at the same increment and the lengths of
corner modules 22 and frame modules 26A, 26B, 26C, 26D, 26E, and
26F are not multiples of a stud or other coupler spacing.
[0113] According to the preferred embodiment of the present
disclosure, posts 162 are shoulder rivets as shown in FIG. 16A that
have an enlarged head 166 and narrower shank 168. Tenons 170 of
posts 162 are inserted into pre-drilled holes in the various tubes
36, 38, 42, 94 and expanded to hold posts 162 on tubes 36, 38, 42,
94. According to alternative embodiments, other stud configurations
may be provided, such as studs without heads. As shown in FIG. 34,
shoulder rivets 162 preferably have a central aperture 169 to
facilitate expansion of an inner end thereof.
[0114] According to the preferred embodiment, loops 164 are
preferably elastic bands, such as bungee cords. According to
alternative embodiments, loops 164 may be made of other materials,
such as non-elastic cords, ropes, lines, etc. As shown in FIG. 18,
loops 164 have first end 174 coupled to screen 18 and a second end
176 coupled to screen 18 so that a combination of loop 164 and
screen 18 cooperate to define a whole aperture 178. According to
other embodiments, loop 164 may have a rigid hook (not shown) so
that a whole aperture is not defined. Loops 164 preferably have
pull tabs 169 to assist in pulling loops 164 over posts 162 as
described below.
[0115] When coupled to posts 162, portions of loops 164 are
positioned forward of frame 16 and portions are positioned outward
of perimeter surface 167. When posts 162 or other frame connectors
are provided in locations other than perimeter surface 167,
portions of loops 164 may be located in other locations, such as
rearward of frame 16 or inward of components of frame modules 22,
26. When wrapped around posts 162, loops 164 apply force to posts
162 in a direction normal to the viewing surface of projection
screen 18. Loops 164 also apply an outward force to projection
screen 18 to provide tension thereto.
[0116] As shown in FIG. 19, screen 18 includes a viewing surface
180 and a border 182 that extends around the four edges of viewing
surface 180 as shown in FIG. 1. Viewing surface 180 and border 182
are preferably made of a woven or non-woven fabric, such as vinyl
sheet with or without reinforcement. Border 182 is folded over each
side of viewing surface 180 and sewn or other otherwise coupled to
viewing surface 180 at the overlap therebetween. As shown in FIG.
17, border 182 includes a plurality of notches or openings 184
through which loops 164 extend. First and second ends 174, 176 of
loops 164 are sewn or otherwise coupled to border 182 resulting in
loops 164 being permanently coupled to the remainder of screen 18.
FIG. 18 illustrates several methods of sewing loop 164 to border
182. From left to right, stitching 186 is parallel to border 182,
stitching 188 is V-shaped with two segments 190 at forty-five
degree angles to border 182, and stitching 192 includes two
separated segments 194 that are at forty-five degree angles from
border 182. Other stitching configurations may also be
provided.
[0117] As shown in FIG. 24, loop 164 may also be coupled to border
182 with plate 196 sandwiched between folds of border 182. Plate
196 includes a substantially circular body 198 and four fingers
200. Initially, plate 196 is substantially flat. First and second
ends 174, 176 are placed over fingers 200, which are rolled over
first and second ends 174, 176 to secure loop 164 to plate 196.
[0118] To couple loop 164 and plate 196 to border 182, plate 196 is
positioned between folds of border 182 with loop 164 extending
through opening 184 of border 182. Rivet 202 is inserted through
respective openings 205, 206 of plate 196 and border 182 and rivet
202 is expanded in a customary manner to secure plate 196 to border
182, as shown in the two right-most examples in FIG. 24. Plate is
preferably made of metal, but may be made of other materials.
[0119] As shown in FIG. 25, loop 164 may also be coupled to border
182 with plate or sheet 204 sandwiched between folds of border 182.
Loops 164 and plate Sheet 204 includes a substantially rectangular
body 207 and two tubes 208 having axes that are parallel to viewing
surface 180 during use. Sheet 204 tapers from top 210 to bottom 212
and is preferably made of a molded plastic material. In the
preferred embodiment, loops 164 and components, such as sheet 204,
sheet 204', discussed below, plate 196, cooperate to define
projection screen connectors that connect the remainder of
projection screen 18 to projection screen frame 16.
[0120] Because sheet 204 tapers or wedge-shaped, it becomes more
flexible from an outer end to an inner end as it approaches viewing
surface 180. Sheet 204 includes a pair of openings 214 below tubes
208. First and second ends 174, 176 of loop 164 are provided with
band clips 216 that have an outside diameter greater than the
inside diameter of tubes 208 so that first and second terminal ends
174, 176 of loop 164 cannot be pulled from sheet 204. When fully
assembled, terminal ends 174, 176 are preferable positioned within
projection screen 18. Normally, band clips 216 are positioned in
openings 214. To position clips 216 in openings 214, at least one
end of first and second ends 174, 176 without a clip 216 is
inserted through an upper end of a collar or tube 208 and through
the lower end of tube 208 so that the respective end 174, 176
extends out of the respective opening 214. Then a band clip 216,
which is larger than the opening in tubes 208, is crimped or
otherwise fastened to the respective end 174, 176 so that the
respective end 174, 176 of loop 164 cannot be pulled from sheet
204. The other end 176, 174 may be provided with a clip 216 in the
same manner.
[0121] To couple loop 164 and sheet 204 to border 182, sheet 204 is
positioned between folds of border 182 with loop 164 extending
through opening 184 of border 182. Then thinner bottom 212 of sheet
204 and the folds of border 182 are sewn together so stitching 220
extends through bottom 218 and both folds of border 182.
[0122] An alternative embodiment sheet 204' is shown in FIG. 30.
Sheet 204' is similar to sheet 204, but includes an extension 205
and an aperture 209 through extension 205 through which loop 164
passes. Extensions 205 extend beyond posts 162 as shown to hide
posts 162 from view. Border 182 extends around extensions 205 so
that portions of projection screen 18 are positioned beyond posts
162. An upper edge 211 of projection screen 18 extends above an
upper portion 213 of projection screen frame 16. Similarly, side
edges of projection screen 18 extend beyond side portions 215 of
projection screen frame 16 and lower edges of projection screen 18
extend below a lower portion 217 of projection screen frame 16.
[0123] Coupling devices other than loops 164 and posts 162 may also
be used to couple screen 18 to frame 16. For example, snaps,
hook-and-loop type fasteners, rope and grommets, and other coupling
devices known to those of ordinary skill in the art may also be
used.
[0124] To couple screen 18 to frame 16, screen 18 is positioned
over frame 16 so that loops 164 align with posts 162. Loops 164 are
then stretched over heads 166 of posts 162. When loops 164 are
positioned over posts 162, screen 18 is under tension provided by
the stretching of elastic loops 164.
[0125] The stiffness of frame 16 depends on the number of frame
modules 26 coupled together to create a particular size frame 16.
For example, frame 16D will normally be less stiff than frame 16A.
On occasion, a frame 16 may be so large that its own weight and/or
the weight of screen 18 supported by frame 16 may cause deflections
in frame 16 that cause undesirable results, such as waves or other
distortions in screen 18. Such distortions may detract from the
image display on screen 18 from projector 12.
[0126] To reduce such deflections, frame 16 may be provided with
stiffening bars, such as stiffening bars 218, 219 shown in FIGS. 21
and 23. Stiffening bar 218 is preferably a module 26, such as
module 26F, that is centered on joint 222 between adjacent modules
26 as shown in FIG. 21. Stiffening bar 218 is coupled to frame
modules 26 to reduce separation in joint 222 and to increase the
overall area moment of inertia or beam strength of that portion of
frame 16. Stiffening bar 218 may be coupled to modules 26 using
clamps 114, 142 or other coupling devices, such as bolts and other
coupling devices know to those of ordinary skill in the art.
[0127] Stiffening bar 219 is illustrated in FIG. 23 and includes
tube 224 and a pair of threaded posts or bolts 226, which each have
a threaded shank 228, knob 230, and hex head 232. Each corner
module 22, frame module 26, and base module 98 of legs 14 includes
a plurality of threaded sockets 234 that are configured to receive
threaded shanks 228. Sockets 234 are each spaced apart from
longitudinal edges 236 of collars 56, 84 of corner modules 22,
modules 26, and base modules 98 by an equal distance 238 so that
sockets on opposite sides of joint 222 are spaced apart by equal
distance 240, which is also the separation distance of shanks 228
on each stiffening bar 219. Therefore, stiffening bar 219 can be
used to stiffen any joint 222 defined any combination of modules 26
with other modules 26, corner modules 22, or base modules 98 of
legs 14.
[0128] To stiffen a joint 222 with stiffening bar 219, one of
shanks 228 is aligned with a socket 234 on one side of joint 222
and threaded into this socket 234 by turning knob 230 or using a
tool on hex head 232. Next, the other shank 228 on stiffening bar
219 is aligned with a socket 234 on the opposite side of joint 222
and threaded into this socket 234. When stiffening bars 219 are
coupled to frame modules 26, joint 222 further resists separation
and the second moment of area of that section of frame 16
increases. During disassembly of frame 16, shanks 228 are removed
from sockets 234 by turning knob 230 or using a tool on hex head
232.
[0129] 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.
[0130] 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 de tract 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.
[0131] As shown in FIG. 22, a kit 242 may be provided that includes
multiple screens 18, such as screens 18A, 18B, 18C, multiple frame
modules 26, multiple corner modules 22, multiple leg base modules
98, clamps 114 (or 142), and container 246 holding the other
components of kit 242. For illustrative purpose, not all corner
modules 22 and frame modules 26 are shown in container 246 that are
necessary to construct the required frames 16. According to one
embodiment of the present disclosure, not enough frame modules 22,
26 are provided in container 246 to build sufficiently sized frames
16 for all of projection screens 18 provided in container 246 at
one time.
[0132] In one example, if the kit includes three projection screens
18, only eight corner frame modules 22 may be provided, even though
twelve corner frame modules 22 would be required to construct
projection screen frames 16 for all of three projection screens 18
at one time. Further, if each projection screen frame 16 required
eight frame modules 26, only eighteen frame modules 18 of various
different sizes might be provided even though twenty four frame
modules 26 would be required to construct projection screen frames
16 for all three projection screens at one time. Preferably, at
least some of frame modules 26 can be used to construct different
sized frames 18. On occasion at least some of frame modules 26
provided in the kit cannot be used to construct a projection screen
frame 16 for one or more of screens 18 provided in the kit.
However, such a frame module 26 will likely to useable for
construction another projection screen frame 18 for one of the
other projection screens 18 provided in the kit.
[0133] Because fewer frame modules 26 are provided that required to
construct frame 16 for all projection screens 18 in the kit, there
will be more projection screen components that corresponding
projection screen frame components. For example, in total
projection screens 18 in the kit will have more loops 164 that the
total number of posts 162 provided in the frame modules 22, 26.
Furthermore, the total perimeter length of the projection screens
18 in the kit is greater than the total length of the frame modules
22, 26. But, the total length of the frame modules 22, 26 is
greater than the perimeter length of at least one of the screens 18
provided in the kit.
[0134] Preferably, the projection screens 18 provided in the kit
are of different sizes. For example, one projection screen 18 may
have a viewing surface greater than 10% larger than another
projection screen 18 provided in the kit.
[0135] Diagrams or instructions 244 of various frame configurations
may be provided on or with container 246. Each diagram or
instruction 244 shows the necessary size and number of modules 26
necessary to build a frame 16 for a particular size screen 18. For
example, left-most diagram 244A illustrates frame 16A for use with
screen 18A; diagram 244B illustrates frame 16B for use with screen
18B; middle diagram 244C illustrates frame 16C for use with screen
18C, diagram 244D illustrates frame 16D for use with screen 18D,
and right-most diagram 244E illustrates a larger frame for use with
a larger screen (not shown). In diagram 244, the various different
sized frame modules 26 may be color coded, number, or provided with
other identifiers. Similarly, each frame module 26 may be provided
with matching color-coding, numbers, or other identifiers. For
example, frame module 26F may be shown in red in diagram 244 and
red marking is provided on frame module 26F. Whereas, frame module
26E may be shown in green in diagram 244 and green marking is
provided on frame module 26E.
[0136] According to one method of using projection screen apparatus
10, a distributor, such as an equipment lessor, provides kit 242 at
a location for a receiver, such as a lessee. In one example, an
equipment lessor rents kit 242 to a lessee for use at a tradeshow.
Upon receipt of kit 242 by the lessee from the lessor, the lessee
can determine which size screen 18 is best suited for their need.
Upon selecting the appropriate size screen 18, the lessee selects
the appropriate size frame 16 that matches the selected screen 18.
For example, upon receipt of kit 242, the lessee may determine that
screen 18C is the right size and format for their needs. The lessee
then selects frame 16C to construct and references diagram 244C to
determine which frame modules 26 to connect to corner modules 22 to
construct frame 16C.
[0137] Normally, kit 242 will include enough modules 26 to build
any one of frames 16 for each different screen 18 provided in kit
242. For example, if kit 242 includes screens 18A-18D, at least two
26A modules, two 26C modules, six 26D modules, ten 26E modules,
four 26F modules, and four corner modules 22 would be provided so
that any one of frames 16A-16D could be constructed to support
screens 18A-18D.
[0138] However, each kit 242 will normally not include enough
modules 26 to build each frame 16 for each different screen 18 at
the same time. For example, it would require at least two 26A
modules, two 26C modules, fourteen 26D modules, twenty 26E modules,
ten 26F modules, and sixteen corner modules 22 to build all of
frames 18A-18D to support screens 18A-18D all at the same time. Kit
242 would not normally include all of these components.
[0139] Modules 26 from kit 242 that are not used to construct a
frame 16 may be used for other purposes. For example, if frame 16D
is built, six of the ten frame modules 26E, two of the four frame
modules 26D, and all (two) of the frame modules 26A that are not
used to construct from 16D may be used to construct legs 14 or as
stiffening bars 218.
[0140] On occasion, one or more of the components of legs 14 and
frame 16 that can be built from kit 242 or otherwise may become
damaged. As a result, kit 242 may include an extra of each of frame
modules 26A, 26B, 26C, 26D, 26E, 26F, corner module 22, and base
module 98. If the preferred screen 18 is damaged, a smaller or
larger screen 18 in kit 242 can be used. For example if screen 18B
is preferred, but damaged, either screen 18A, 18C, or 18D may be
used with a matching frame (i.e. frame 16A, 16B, or 16D).
[0141] Upon return of kit 242 to the lessor can replace the damaged
component of legs 14 or frame 16 without having to return the leg
or frame 16 to the original manufacturer for repair. The lessor can
replace the damaged component from stock on hand, from another kit
242, or order a replacement component from the original
manufacturer.
[0142] On occasion, new screen formats are created that have
different ratios of height to width than previous formats. When
such a new format is created, kits 242 can be updated for the new
format by providing new frame modules 26 of sufficient length to
satisfy the new format. For example, if a wider format is created,
a longer module 26 can be manufactured and provided in an existing
kit 242. Along with the new, longer module 26, an updated diagram
244 showing the proper combination of frame modules 26 is provided
to the assembler of the new format frame 16. With the new diagram,
the assembler knows which of the frame modules 26, including the
longer module 26, to assemble together to create the new format
frame 16.
[0143] On occasion, it is possible that new combinations of
existing frame modules 26 may result in the new format. For
example, it may be possible to replace frame module 26A in frame
16B with frame module 26B to create a format having a taller
profile. Along with any additional, required frame module 26B, an
updated diagram 244 showing the proper combination of frame modules
26 is provided to the assembler of the new format frame 16. With
the new diagram, the assembler knows which of the frame modules 26,
including frame module 26B, to assemble together to create the new
format frame 16.
[0144] In some uses, projection screen apparatus 10 is not provided
in a kit that includes multiple screens 18. In such a situation,
only enough frame components necessary to construct a frame 16 that
supports the provided screen 18 are provided. Spare frame
components to build this frame 16 may be provided in the event that
one of the frame components breaks or otherwise needs repair or
replacement.
[0145] 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.
[0146] A method of constructing projection screen apparatus 10 may
include the steps of receiving at least one pre-manufactured
projection screen 18 and a plurality of pre-manufactured frame
modules, such as corner frame module 22 and frame module 26,
selecting a subset of the plurality of pre-manufactured frame
modules 22, 26 sufficient to construct a projection screen frame 16
corresponding to at least one pre-manufactured projection screen
18, constructing projection screen frame 16 using the subset of the
plurality of pre-manufactured frame modules 22, 26, gband coupling
pre-manufactured projection screen 18 to projection screen frame
16. A pre-manufactured projection screen 18 may be cut to size from
a larger piece of material and have suitable connectors, such as
connectors formed by loops 164 and sheets 204, attached thereto or
suitable prepared to receive separate connectors. Pre-manufactured
frame modules may be cut to length and provided with ends that mate
or otherwise couple to adjacent frame modules 22, 26.
[0147] A method of facilitating constructing projection screen
apparatus 10 may be provided. The method includes the steps of
receiving projection screen 18, and a plurality of pre-manufactured
frame modules, such as frame modules 22, 26, which may be sent from
a party such as a manufacturer, rental dealer or otherwise,
selecting a subset of the plurality of pre-manufactured frame
modules sufficient to construct a projection screen frame 16
corresponding to the at least one pre-manufactured projection
screen 18, providing the subset of the plurality of
pre-manufactured frame modules 22, 26 to another party, such as a
rental dealer or an end user, and providing instructions 244 on the
construction of projection screen frame 16 from the
pre-manufactured frame modules to the party.
[0148] Another method of facilitating construction of a projection
screen apparatus 10 may be provided. The method includes the steps
of providing a projection screen 18 requiring a projection screen
frame 16 of a predetermined size to support the projection screen
18 during use, providing a plurality of frame modules greater than
the number of projection frame modules 22, 26 necessary to
construct the projection screen frame 18, sending the projection
screen 16 to another party, and sending the plurality of frame
modules 22, 26 to the party for use in constructing the projection
screen frame 16 to support the projection screen 18 during use.
This method may be performed by a manufacturer, a rental dealer, or
another party.
[0149] Another method of facilitating construction of a projection
screen apparatus 10 may be provided including the steps of
collecting a plurality of projection screens 18 requiring a
plurality of projection screen frames 16 of a predetermined size to
support the plurality of projection screens 18 during use,
collecting a plurality of projection screen frame modules 22, 26
less than the number of projection screen frame modules 22, 26
necessary to construct the plurality of projection screen frames 16
at one time, providing the plurality of projection screens 18 to
another party, such as a rental dealer or end user, and providing
the plurality of frame modules 22, 26 to the party for use in
constructing at least one of the plurality of projection screen
frames 16.
[0150] A method of constructing a projection screen apparatus 10
may be provided. The method includes the steps of providing a
projection screen 18 and a plurality of frame modules, such as
frame modules 22, 26. The plurality of frame modules 22, 26 may
include at least two identical frame modules 22, 26. The method may
further include constructing a projection screen frame 16 with the
plurality of frame modules 22, 26 including at least one identical
frame module, supporting the projection screen 18 with the
projection screen frame 16, constructing at least one leg, such as
leg 14, with the plurality of frame modules 24 including at least
one identical frame module 26, and supporting the projection screen
frame 16 with the at least one leg.
[0151] An addition to projection screen frame 16, other components
may be provided to support a drape 99. As shown in FIG. 31, a drape
support 248 is provided that couples to posts 162. Drape support
248 includes a body 250, preferably molded from plastic, and a
magnet 252. Body 250 includes a recess or slot 254 having a wide
portion 256 sized to receive head 166 of post 162 and a narrow
portion 258 sized to receive shank 168 of post 162 as shown in
FIGS. 32 and 33. Magnet 252 may be molded into body 250. When drape
support 248 is coupled to post 162, magnet 252 is magnetically
attracted to ferrous metal in post 162. Body 250 includes an
extension 260 to which drape 99 is attached as shown in FIG.
32.
[0152] Multiple drape supports 248 are typically provided on lower
portion 217 of frame 18 to provide drape 99 extending under
projection screen 18. However, draper supports 248 may be coupled
to posts 162 on top portion 213 and side portions 215 of projection
screen frame 18.
[0153] Drape support 248 is one of several accessories that couple
to post 162 in addition to a loop 164 being coupled to the
respective post 162. For example, as shown in FIG. 32, posts 162
couples to loop 164 and to drape support 248.
[0154] Another such accessory that also couples to posts 162 is
another projection screen 18. As shown in FIG. 34, a pair of loops
164 are coupled to a single posts 162. Thus, one projection screen
18 is positioned on one side of frame 16 and another projection
screen is coupled to the opposite side of frame 16. As a result,
two projection screens 18 can be supported by a single projection
screen frame 16. To mask the back of a frame 16 sheet of material
may, such as a projection screen or other sheet of material.
[0155] Yet other accessories that also couple to posts 162 while
loops 164 are coupled to posts 162 are shown in FIG. 35. U-shaped
drape support 262 couple to posts 162 of top portion 213 of
projection screen frame 18 and L-shaped drape 264 couples to posts
162 of side portions 215 of projection screen frame 18. Each drape
support 262, 264 includes a plurality of posts 162'. Drape 99 may
be provided with loops 164 that wrap around posts 162' to support
drape 99 above projection screen 18 or to the sides of projection
screen 18.
[0156] Similar to drape support 248, drape support 262 includes two
recesses 266 having wide portions 268 sized to receive head 166 of
post 162 and narrow portions 269 sized to receive shank 168 of post
162 as shown in FIG. 36. Recess 266 further includes a
loop-receiving portion 270 which allows loop 164 to couple screen
18 to post 162 frame 16 while drape support 262 is coupled to the
same post 162.
[0157] Multiple drape supports 262 are typically provided on top
portion 213 of frame 18 to provide drape 99 extending above
projection screen 18. However, draper supports 262 may be coupled
to posts 162 on bottom portion 217 and side portions 215 of
projection screen frame 18.
[0158] L-shaped drape support 264 includes recesses or slots 272,
one shown in FIG. 37, also sized to receive posts 162. Recess 272
has a wide bottom 274 sized to allow head 166 of post 162
therethrough and a narrow top 276 sized to receive shank 168 and
not allow head 166 to pass therethrough. During assembly, heads 166
of posts 166 are aligned with wide bottoms 274 of recesses 272 of
L-shaped drape support 264 and heads 166 are inserted into L-shaped
drape support 264. L-shaped drape support 264 is then lowered to
that shanks 168 are positioned in narrow top 276. Because heads 166
cannot be removed through narrow top 276, drape support 264 is
coupled to frame 16. To remove drape support 264, drape support is
pushed upward. According to an alternative embodiment of the
L-shaped drape support 264, upper bar 278 slides horizontally along
the remainder of L-shaped drape support 264. Upper bar 278 slides
in a track (not shown) provided below upper bar 278. The sliding
connection allows posts 162' to translate from side to side.
[0159] While this invention has been described as having an
exemplary design, the present invention may be further modified
within the spirit and scope of this disclosure. This application is
therefore intended to cover any variations, uses, or adaptations of
the invention using its general principles. Further, this
application is intended to cover such departures from the present
disclosure as come within known or customary practice in the art to
which this invention pertains.
* * * * *