U.S. patent number 3,724,524 [Application Number 05/118,626] was granted by the patent office on 1973-04-03 for picture screen roller fabric attachment.
This patent grant is currently assigned to Da-Lite Screen Company, Inc.. Invention is credited to Fred S. Potter.
United States Patent |
3,724,524 |
Potter |
April 3, 1973 |
PICTURE SCREEN ROLLER FABRIC ATTACHMENT
Abstract
A projection screen having a spring roller with a fabric-locking
groove comprised of opposed side walls stepped on the roller
periphery to the thickness of the fabric for producing safe
mounting and flat hanging of picture surfaces, the side walls of
which groove outwardly converge on a gap in the roller periphery of
width equal to about twice the thickness of the screen fabric
forming an inwardly-bent, wedging channel for locking on a metal
strip clamped to the inner edge of the fabric screen and inserted
therein so that the more the fabric is pulled, the tighter and more
uniformly the screen will be held and the flatter the fabric will
hang during use.
Inventors: |
Potter; Fred S. (Warsaw,
IN) |
Assignee: |
Da-Lite Screen Company, Inc.
(Warsaw, IN)
|
Family
ID: |
22379771 |
Appl.
No.: |
05/118,626 |
Filed: |
February 25, 1971 |
Current U.S.
Class: |
160/24; 160/393;
160/397; 160/395; 160/403 |
Current CPC
Class: |
G03B
21/58 (20130101) |
Current International
Class: |
G03B
21/56 (20060101); G03B 21/58 (20060101); E04f
010/06 () |
Field of
Search: |
;160/24,66,67,243,310,382,383,391,392,394,395,397,400,403,384,389,393,396,401 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Caun; Peter M.
Claims
I claim:
1. In a projection screen including a housing, a tubular roller
having end caps and a peripheral wall rotatably mounted within said
housing and a screen fabric having opposite faces, side edges, an
inner edge and an outer edge and a suspension slat secured to said
screen fabric at its outer edge, the improvement in roller
structure and means for attaching the inner edge of said fabric to
said roller so that the fabric will hang flat during use
comprising:
a. a groove formed in the interior of said tubular roller, said
grove comprising a bottom wall and side walls converging from the
opposite edges of said bottom wall towards the periphery of said
tubular roller to form a narrow gap at the periphery of said roller
extending longitudinally thereof, one of said side walls being
offset below the other side wall at the periphery of said roller an
amount substantially equal to the thickness of the fabric and the
peripheral wall of the tubular roller in the region of the groove
being offset the same amount, the side walls being smoothly faired
into the periphery of the tubular roller and the peripheral surface
of the roller making a smooth transition from one side of said gap
to the other side, and
b. a folded strip clamped to the inner edge of the fabric, said
strip extending longitudinally in the groove and being of a width
such that when the fabric is subjected to a tension force between
its inner and outer edges said strip is positioned at an angle to
the base of the groove with one of the longitudinal edges of the
strip disposed in the corner formed by said base and one of said
converging walls and the other longitudinal edge of the strip being
adjacent the other of said converging walls with the fabric
disposed between said other longitudinal edge and said other
converging wall, an increasing tension on the fabric causing said
strip and the interposed fabric to bear more strongly against said
other wall.
2. In a projection screen as claimed in claim 1, the further
improvement wherein the tubular roller has a longitudinal locking
seam circumferentially spaced from said gap and end caps are
mounted in the ends of said roller, each of said caps
comprising:
a. a back face,
b. a flange element circumferentially mounted to one side of said
back face slip-fitted within said tubular roller peripheral
wall,
c. a spindle element centrally mounted to said back face extending
in a direction opposite to that of said flange, and
d. cutouts circumferentially spaced in said flange for sliding over
the fabric locking groove means and the locking seam.
Description
BACKGROUND OF THE INVENTION
The spring-loaded roller on which a picture screen fabric sheet is
wound almost invariably has been made of wood or hollow metal tube.
Accordingly, the inner edge of the screen fabric has been attached
by staples to the periphery of the wood roller on a recessed ledge
running along the roller length at a depth equal to the thickness
of the screen fabric. This method of attachment has not been too
secure in the safe mounting nor too flat in the hanging of picture
surfaces. When color slides or film are projected on a screen
surface, it should be smooth and taut and hang flat without
unsightly deformations in order to present a clear, undistorted
picture.
In order to have the picture surface hang flat from a hollow metal
tube roller, clips, keys, keepers and snap-in bars in conjunction
with fabric-locking grooves have been used. Hartshorn, U.S. Pat.
No. 444,832, shows a snap-in bar in a fabric-locking groove
arrangement which suffers from the disadvantage that as an
attachment, it is not secure. Kampas, U.S. Pat. No. 1,807,535,
shows a keeper for clamping on the end of the fabric slidably
installed in the fabric-locking groove which differs from the
attachment of the present invention in the absence of a wedging
action, which makes the attachment more secure the tighter it is
pulled. Yeates, U.S. Pat. No. 1,834,669, shows a fabric groove with
interlocking key which lacks the positive lock-up feature that is
characteristic of this invention. Anderson, U.S. Pat. No.
3,018,824, shows a clip arrangement for attachment of the fabric to
the roller which is complicated and expensive to assemble.
There is thus a need for an improved roller for a roll-up
projection screen which is low in cost and without a substantial
hanging deformation of the viewing surface of the screen, and which
is easily replaceable. Also, it was to overcome the foregoing
described deficiencies that the present invention was
conceived.
SUMMARY OF THE INVENTION
The invention relates to projection screens of the type which, when
not in use, are stored would up on a roller. One essential concept
of this invention involves a metallic tubular roller formed from a
single rectangular flat piece of heavy gauge sheet metal containing
a screen fabric locking groove and a stepped portion adjacent one
side of the groove to substantially eliminate hanging deformations
in the viewing surface of the screen and give a secure and safe
mounting of the screen. The groove is of inwardly-bent,
channel-shaped cross-section having side walls disposed inwardly of
the roller periphery but in outwardly-converging relation running
the full length of the roller for locking on and wedging in a
folded metal strip clamped along the full length of the inner edge
of the screen fabric which is inserted in the groove. Diametrically
opposite the groove, the free edges of the tube are integrally
formed by an outwardly-extending male tongue and female groove
locking joint.
It is thus an object of this invention to provide an improved
low-cost roller for a roll-up projection screen which is formed
from a single rectangular flat piece of heavy gauge metal
containing a screen fabric locking groove and a stepped portion
adjacent one side of the groove, whereby to substantially reduce
hanging deformation in the viewing surface of the screen when in
use.
Other objects and important features of the invention will be
apparent from a study of the following specification taken with the
drawings, which together describe and illustrate a specific
embodiment of the invention, and what is now considered to be the
best mode of practicing the principles thereof. Other embodiments
may be suggested to those having the benefit of the teachings
herein, and such other embodiments are intended to be reserved
especially as they fall within the scope and spirit of the
subjoined claims.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of this invention is shown in the accompanying
drawings, in which:
FIG. 1 is a reduced, perspective view of a slide and movie
projection screen incorporating the present invention;
FIG. 2 is an enlarged transverse section substantially taken on the
line 2--2 of FIG. 1 but showing the several convolutions of
successive layers of screen fabric wound around the roller in
rolled-up position;
FIG. 3 is an enlarged fragmented section of the fabric groove in
the spring roller and illustrating the locking of the fabric on the
folded metal strip;
FIG. 4 is an enlarged transverse section of the roller showing the
fabric unwound from the roller and extended for use; and
FIG. 5 is an enlarged fragmented perspective view illustrating the
method of assembly of the roller fabric attachment and showing one
of the end plugs.
DESCRIPTION OF THE PREFERRED EMBODIMENT
This invention concerns the design and construction of slide and
movie projection screen which are designated in general by the
reference numeral 10 on FIG. 1 in which the housing or case 11
carries projection screen fabric 12 attached to and would up on
roller 13 under the usual spring tension (the spring not being
shown) in successive layers 14 for storage. The fabric 12 extends
out slot 15 in case 11 drawn by slat 31 during use. As clearly
shown in the drawing, the screen fabric 12 has opposite front and
back faces, vertical side edges, an outer edge secured to
suspension bar 31 and an inner edge secured to locking strip 25, as
described more fully below.
Eccentric hollow spring roller 13 incorporates a fabric locking
groove 16 extending within the interior of the roller having
outwardly converging side walls 17 and 28, of which wall 17 is
radially stepped below wall 18 an amount equal to the thickness of
the fabric adjacent where the groove opens to roller periphery
walls 13' and 13", respectively. Radius R of roller peripheral wall
13" in FIG. 3 differs from radius [R-(t/2)] of roller peripheral
wall 13' by an amount equal to one-half the fabric thickness t/2
and each of these radii are centered on a common diameter of roller
13 passing through groove 16 separated by an amount equal to
one-half the fabric thickness t/2 (about 0.008 inches). Translating
in figures, the thickness of the fabric t is preferably 0.016
inches while the radius R is preferably 0.689 inches, and the
radius [R-(t/2)] is preferably 0.681.
Tubular shaped roller 13 incorporating fabric-locking groove 16 is
formed from a single rectangular flat sheet of heavy gauge metal
(about 0.021 inches) having first and second sides 19 and 19',
first and second edges 19a and 19a', and a first end 20 and a
second end (not shown). Edges 19a and 19a' of the rectangular sheet
are formed tongue and groove in a conventional manner so that upon
circumferentially extending side 19 along radius [R-(t/2)] of
peripheral wall 13' and side 19' along radius R of wall 13" (and
side 19') to meet on the far side of the roller from groove 16
according to the geometry of FIG. 3, there engaging flush lock seam
joint 21 so formed at the juncture of the two sides
circumferentially extended, and there closing the open tubular
section the structural integrity of the tubular form of roller 13
as shown in FIG. 5 is completed. The seam 21 lies diametrically
opposite the groove 16.
Fabric groove 16 in FIG. 3 has outwardly converging side walls 17
and 18 terminating in gap 27 at roller periphery 13' and 13",
respectively, with side wall 19 stepped inwardly of side wall 19'
adjacent of gap 27 by an amount equal to the thickness t of the
fabric. The width of the gap is equal to about twice the thickness
of the fabric. Side wall 17 is smoothly faired into juncture with
periphery 13' of roller 13 by external radius r.sub.s (preferably
about 0.052 inches) with side wall 18 similarly smoothly faired
into periphery 13". Both side walls 17 and 18 are inwardly bent to
internal radii r.sub.a (preferably about 0.031 inches) at their
junctures with base 24 and are connected thereacross by base 24
forming fabric-locking groove 16. Folded metal strip 25 clamped
along inner edge 26 of fabric 12 wedges in fabric-locking groove 16
attaching the fabric to the roller with uniform fit-up along its
full length so that during use the fabric hangs flat without
substantial deformation in its picture-viewing area. The angle of
side wall 17 is preferably about 38.degree. while the wall 18 is
preferably about 42.degree., both converging outwardly from the
base 24.
Fit-up of the metal strip 25 in fabric-locking groove 16 for
attachment of fabric to roller is shown in FIG. 3. Metal strip 25
is wider than the perpendicular distance from apex 22 to opposite
side wall 17 of fabric groove 16 so that a pull on fabric 12 wedges
end 25' of strip 25 and the adjacent fabric 12 into the side wall
17 of groove 16. Thus, the more the pull on fabric 12, the greater
the wedging action of metal strip 25 into groove 16.
The width of the metal strip 25 is narrower than the distance from
apex 22 to apex 23 across base 24 of groove 16 so that metal strip
25 can easily be hand-slid in groove 16 in the assembly of
fabric-attaching elements shown in FIG. 4. Simultaneous with the
sliding assembly of strip 25 in groove 16 that portion of fabric 12
adjacent thereto is also inserted in gap 27 and slid therealong to
complete the attachment of fabric to roller. Metal strip 25 may be
optionally slid in groove 16 with fold 25" adjacent apex 22 as
shown in FIG. 3 or, in the reverse sense, with fold 25" adjacent
apex 23 (not shown).
The wedging action of metal strip 25 in fabric groove 16 with a
completely unreeled screen is shown in FIG. 4. This configuration
imposes the most critical condition under which attachment of
fabric to roller must function without hanging deformation of the
screen in the picture-viewing area. Metal strip lock-up in groove
16 here results in a flatter screen fabric hang than for
conventional means of attachment because fabric 12 is maintained
straight along its inner edge 26 by the straightness of the fold in
metal strip 25, and also maintained flat along its full length by
the fit-up of strip 25 wedging in longitudinal groove 16 against
side wall 17 or 18. As very clearly shown in FIG. 3, the tension
force transmitted by screen 12 to unroll the screen causes strip 25
to be wedged in groove 16 with one longitudinal edge of the strip
forced into the apex 22 and the other longitudinal edge of the
strip forced towards wall 17 to wedge or grip fabric 12 between the
edge of the strip and the wall so that the more the fabric is
pulled, the tighter the screen will be held.
Spring roller 13 is rotatably mounted in case 11 on end gudgeons or
end plugs 32, one of which is slip-fitted in the end 20 of roller
13 shown in exploded view in FIG. 5. Plug 32 is a cup-shaped sheet
metal stamping having back face 32a and flange 29 for slip-fitting
in the inside diameter of tubular roller 13. Spindle 28 is axially
mounted to said back face for rotatably carrying the roller. Flange
29 has specially formed cutouts 30 circumferentially spaced
therein, each cutout of which can slip over the inward protrusions
of either fabric groove 16 or lock seam 21 selectively for locking
up and supporting end plug 32 in the end 20 of tubular roller 13.
Plug 32 so installed in end 20 also prevents the spreading apart of
sides 17 and 18 of groove 16 under the wedging action of metal
strip 25 or the accidental opening of the lock seam 21. A second
end plug (not shown) slips in the opposite end (not shown) of
roller 13 in a similar manner performing the same general purpose
but rotatably carrying an axially-mounted, flat-sided shaft
attached in a conventional manner to the usual spring (not
shown).
Although but one embodiment of this invention has been herein shown
and described, it will be understood that numerous details of the
construction shown may be altered or omitted without departing from
the spirit of the invention as defined by the following claims.
* * * * *