REDUCING TO PRACTICE CERTAIN DISCOVERIES RELATING TO THE OPTICAL PHENOMENA OF REAR PROJECTION SCREENS

• Document Type: CREST
• Collection: NGA Records (Formerly NIMA)
• Document Number (FOIA) /ESDN (CREST): CIA-RDP79B00873A001900010121-0
• Release Decision: RIPPUB
• Original Classification: K
• Document Page Count: 28
• Document Creation Date: December 28, 2016
• Document Release Date: September 6, 2012
• Sequence Number: 121
• Publication Date: January 31, 1968
• Content Type: REPORT

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An Unscaielted Prppo[sal
F6r.
"REDUCINIX F;RACTICE CERTATN bIS-.
COVERIES RELATING TO 104 optIc4L
PHENOMENA OF REAR 'PROgECTION 'SCREENS
'S#brai!tteast to!:
*IED STATES WVERNMENt
Electronics
Research
CORNING
ELECTRONICS
A DIVISION OF CORNING GLASS WORKS
RALEIGH, NORTH CAROLINA
II I I III BIM R. Ill. 1111 11 .111.11r1A T
14PIC/#27/68 Copy #3 (A) 7
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These data furnished as part of an unsolicited proposal shall
not be disclosed outside the Government or be duplicated, used
or disclosed in whole or in part for any purpose other than to
evaluate the proposal; provided, that if a contract is awarded
to this offeror as a result of or in connection with the sub-
mission of such data, the Government shall have the right to
duplicate, use or disclose these data to the extent provided
in the contract. This restriction does not limit the Govern-
ment's right to use information contained in such data if it
is obtained from another source.
The accompanying proposal relates to the evaluation and appli-
cation of materials; some of which are the result of Corning's
inventions in the composition, processing, and manufacturing
of glass. Improvements which may be made thereon in the
course of work being performed under the proposed program
would be regarded as 'Subject Inventions" under which the
Government would obtain free and non-exclusive rights for
Government end-use in accordance with the provisions of
ASPR9-107.5(b) 1. It is not our intent to grant to the Govern-
ment rights under any background inventions or technology,
including glass composition and processing.
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AN UNSOLICITED PROPOSAL
For
ICE CERTAIN DISCOVERIES
"REDUCING TO PRAC
RELATING TO THE OPTICAL PHENOMENA OF
REAR PROJECTION SCREENS"
Submitted to
THE UNITED STATES GOVERNMENT
By
Corning Glass Works
Technical Staffs Division
Electronic Research Laboratory
3800 Electronics Drive:
Raleigh, North Carolina 27502
January 31, 1968
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I . INTRODUCTION
. OBJECTIVE
B. COMPANY 3ACKGROUND .
C. ATTACK TO BE FOLLOWED
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I - I
II. RESULTS EXPECTED .
...
. ..... . . . II -
III. TECHNICAL DISCUSSION . . ?ill -i
A. ANALYSIS OF SCREEN PERFORMANCE REQUIREMENTS . . III - I
B. INVESTIGATION OF DARKENED SU3STRATES III - 3
C. REDUCTION OF SURFACE REFLECTIONS III - 5
D. LENTICULAR SCREENS III - 8
E. DISCRETE-PARTICLE SCREEN PERFORMANCE IMPROVEMENT III -11
IV. RECOMMENDED PROGRAM
V. PERSONNEL
VI. FACILITIES
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I. INTRODUCTION
A. OBJECTIVE
Corning Glass Works wishes to propose that the discoveries
made concerning the mechanism and phepomena involved in
rear projection screen design and performance under a
contract now just concluding be carried forward and put
to practical application. This will include the further
exploitation of the theories developed and will entail
the selection and combination of the material's found to
be most suitable to fabricate screens having enhanced
performance in the areas of the most critical response
requirements_
. COMPANY BACKGROUND
Under the afore mentioned contract, Corning has been
engaged since mid-1955 in the application of glass; glass-
ceramic and ceramic particles as light scatters to con-
struct improved rear projection screens. Particular
attention has been given to brightness and brightness
variation, efficiency, resolution, contrast, and diffuse
reflection. A major part of the work has been devoted to
determining the effects on these parameters of the par-
ticles themselves and their properties, the properties of
?the materials serving as vehicles for the particles and
the properties of the substrates for the screens.
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In addition to deriving the significant performance
parameters, the equipment (at Corning's expense) was
designed and built for determining them. As an example,
a MTF analyzer is now available which by design and
operational procedure is particularly suited for rear
projection screen evaluation. The Laboratory is unusally
well equiped at this time for going forward in this field
as will be noted from the "Instrumentation" section in
the final report.
In the course of the work several distinct approaches
were taken to the creation of optimum screens. The first
of these was the use of the glass-ceramic process for
?
developing the type of crystaline volume scatters as
dictated by theory. The practical results agreed very
Well with predicted results, but the demands of resolution
necessitated such a thin cross section as to be impractical.
Several methods were then successfully developed for
incorporating the scattering particles in thin layers.
While good results were obtained, it became evident that
one important parameter, contrast, could be greatly
improved through manipulation of the transmission of the
substrate. This will be discussed in more detail in the
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proposed program.
A different approach to the problem was ?the use of
shaped light refractors. One attempt incorporating
FOTOFORM glass was successful in developing the lenticu-
lar surface but unwanted crystal growth degraded the
resolution. Theoretical examination of screens formed
from refracting beads and properly masked showed great
promise. Reduction to practice in the time still avail-
able was not possible but the approach deserves further
effort.
Throughout the course of the project, considerable
experience was had in the subjective evaluation of
Screens. It is felt that this in conjunction with the
new instrumentation will be of value in reassessing the
comparative importance of screen performance criteria.
Such information would be of great value in optimizing
the results.
C. ATTACK TO BE FOLLOWED
The experience and background information gained from
the recently completed contract will be drawn on very
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heavily. It is expected that the contracting agency
will be able to supply further background in the phy-
siology of seeing and the human factors involved in
viewing. The program will then begin by combining and
drawing on these information sources to establish
basis for reappraising the criteria for screen perfor-
mance. A systems point of view will be taken which
will encompass the screen, the viewing machine and the
viewer.
From the original work, it is quite evident already that
contrast is one of the most important criteria. The
systems-type analysis will c116rify and quantify this
parameter which will be the first objective of the ex-
perimental portion of the project. Since the theoretical
. ,
and practical indications point -.towards ?the need for
controlled absorbtion in the substrate, effort will be
directed towards this. Towards the same objective of
_
contrast enhancement)work.will also be originated on
optical coatings to minimize the sensitivity, to ambient
light.
Refraction rather than scattering offers an alternate
approach having theoretical advantages in light control
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and efficiency. A potential disadvantage is limited
resolution since it depends on the attainment of very
small lenticules. It is thought to be worthwhile in-
vestigating further such screens due to the fact that
potential improvement is appreciably greater than the
improvement theoretically available in discrete-particle
screens.
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IT. RESULTS EXPECTED
The analysis of screen -performance requirements is expected
to lead to the optimum choice of parameters of Corning
screens and a careful comparison of Corning and other
commercial screens.
The analysis will also guide the screen
development program during the program.
Experimental study is expected to confirm theoretical pre-
dictions relating to the advantages of using an absorbing
substrate to reduce stray light and maintain screen contrast.
In the course of this work several approaches to obtaining
neutral density substrates will be investigated and it is
expected that one of these substrates will be integrated
into practical rear projection screens.
There is no real doubt that a useful reduction of surface
reflections for glass substrate screens can be achieved.
Anti-reflection coating of flexible substrate screens appears
_to offer difficulties. Large flexible substrate screens are
easier tb make than rigid substrate screens. A compromise
may be to coat a glass substrate and form a flexible sub-
strate screen separately and then assemble the flexible sub-
strate onto the glass substrate.
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Results from the lenticular screen work will be strongly
dependent on the successful formulation of a configuration
which is both optically efficient and capable of fabrication.
The theoretical work required to relate screen physical
properties to optical properties will disclose any theore-
tical performance limitations which have not yet been
recognized, and will allow maximum flexibility in choice of
optical properties.
Development of workable masking techniques is expected to
result in lenticular screens having low ambient light sensi-
tivity. The fabrication investigation is expected to deter-
mine the feasibility of fabricating lenticular screens which
have the conceptual advantages discussed in Section III.
Sample screens of candidate configurations will be made.
Theoretical and experimental investigations are expected to
result in a clearer understanding of the discrete-particle
screen. Discrete-particle screens with better efficiency
and diffuse reflectance are expected from the work discussed
in Section III-E.
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Constant attention will be given to the cost and produci-
bility of the screens potentially resulting from the in-
vestigative part of the project. The final product will be
practical on both counts.
Summary reports will be provided each accounting period
(4 weeks). A final report will also be provided.
Sufficient screen material of the best selection will be
provided for testing on a 30" x 30" viewer. It will be in
a single continuous piece if practical. Available equip-
ment may limit the size of a single sheet to something
smaller, but sufficient sheets will be made to cover the
30" x 30" aperture.
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TECHNICAL DISCUSSION
A. ANALYSIS OF SCREEN PERFORMANCE REQUIREMENTS
The use of darkening material in a rear projection screen
can improve the contrast of the display at the expense
of brightness. The most favorable screen parameters
? depend on many of the projection system and observer
parameters. The overall objective is to make the input
contrast of 1000 to 1 perceivable to the observer in the
presence of ambient light.
It is planned to relate Corning screen parameters to
physiological and viewer data supplied by the Government
Agency. This comparison will enable an optimum choice
of existing Corning screen parameters to be made and
compared to the system performance with the Polacoat 60
screen. From this system comparison the advantages to
be gained by enhancement of Corning screen characteristics
can be determined.
There is no doubt that darkening of the screen substrate
and reduction of ambient light reflection will be
desirable. However, the precise degree of darkening
requires quantitative determination.
If the darkening is somewhat wavelength sensitive, zero
dissipation reflective color correction filters can be
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inserted into the projector. The use of water cells
and dielectric thin film filters can filter the non-
visible components from the source lamp in the pro-
jector, perhaps enabling more light to be provided in
the projector beam. A scheme to immerse the trans-
parency in a liquid would considerably increase the
power rating of the transparency.
Careful- design of the observer's room will help reduce
the ambient light incident on the screen. Black walls,
at least in the areas contributing to specular reflec-
tion, will greatly reduce the specular reflection.
A relatively long focal length projection lens will
make the system more tolerant of screen sag defocusing
effects than a short focal length lens system. If the
screen plane is horizontal, with the observers looking
down at it, the sag is in the reverse direction from
the normal focal plane curvature so that a rigid sub-
strate may be preferable to a flexible substrate.
If a systems approach is taken, some of the findings
relating to optimizing screen performance may suggest
modifications in the viewer along the afore mentioned
lines.
16111-1?A
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B. .INVESTIGATION OF DARKENED SUBSTRATES
Theoretical investigations indicate that a loss of image
contrast, an increase in sensitivity to ambient light,
and a lower than necessary efficiency can occur when
rear projection screens consist of a diffusing layer,
containing an absorbing material, and a transparent, non-
absorbing substrate. All known rear projection screens,
that exhibit high resolution, are fabricated by forming
a diffusing layer on a clear substrate. These screens
are made less sensitive to ambient light by adding some
absorbing material to the diffusing layer. This solution
is undesirable not only because the efficiency of the
projection is reduced, but also because a significant
fraction of the ambient light is backscattered close to
the screen surface nearer the viewer, and passes through
very little .of the absorbing material.
A more effective way of reducing the diffuse reflectance
would be to place an absorbing layer next to, and on the
viewing side of the diffusing layer. This ensures that
all the diffusely reflected ambient light passes com-
pletely through the absorbing layer twice. The absorbing
material should now be more effective in reducing the
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diffuse reflectance for a given loss of projection
irradiance; therefore, less absorption is needed and
the efficiency of the screen can be improved. This
absorbing layer should also greatly reduce the fraction
of ambient light trapped in the substrate by total
reflection, after being diffusely reflected, hence
reducing the apparent diffuse reflectance still further.
In addition, part of the projector light is trapped by
the substrate, propagates across the screen, and con-
tributes unwanted light to adjacent areas, which reduces
image contrast. When an absorbing substrate is used,
the long light path causes a substantial reduction in
the trapped light thereby maintaining image contrast.
Experimental investigations are needed to identify suit-
able absorbing substrates and to determine the degree to
which these advantages can be practically attained. If
"neiiTral" density is difficult to achieve, some color
correction in the projector source should be considered.
It is also necessary to investigate the trade-offs
between efficiency, ambient light rejection, and contrast
in order to be able to specify the optimum amount of
absorption needed for a variety of different viewing
requirements.
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C. REDUCTION OF SURFACE REFLECTIONS
. In the absence of some means to reduce surface reflec-
tions they will determine a lower limit to the diffuse
or specular reflectance obtainable with a rear projection
screen. A rough surface towards the viewer will give
diffuse reflectance and a smooth surface will give specu-
lar reflectance. Surface reflections will also cause
loss of screen efficiency although this loss will be
much less significant for the system than the ambient
light reflection.
Fresnel reflections occur whenever a discontinuity of
refractive index occurs such as at a surface. The pro-
portion of vertically polarized light reflected at a
plane surface is given by:
tan2 (e i ?o
R (Perpendicular) -
tan2 (0i et)
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where 0 is the incident angle and e the angle of the
transmitted ray. At normal incidence the proportion of
light reflected reduces to:
R :(11)2
(N+1)2
where N is the ratio of the two refractive indices at
the discontinuity. The corresponding relations for
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horizontally polarized light are:
and
Sin (ei ?e)
R (Parallel) -
R - (N-1)2
(N+1) 2
sin2 (ei et)
Typically, an air to transparent material interface
gives about 5% reflection up to about 45? for equal
amounts of vertical and horizontal polarization (often
referred to as unpolarized light). As the larger angle
(ei or et) approaches 900. , reflection approaches 100%.
For vertical polarization where ei + 0 = 90?, no
ri t
reflection occurs and the angle is known as the Brewster
angle.
Two types of approaches to reduce surface reflections
exist. One approach is to set up extra Fresnel reflec-
tions which cancel the surface reflections. One or
more layers of thin material of carefully chosen refrac-
tive index and thickness are commonly used. Reflection
reduction to below 1% over the visual waveband from 0 to
450 angle of incidence can be obtained. Various schemes
and performance characteristics are discussed in MIL-
HDBK-141, (Military Standardization Handbook, Optical
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Design) section 20.3.
The techniques available for depositing the thin layers
.largely determine the success'of the reflection cancel-
lation approach. For glass and other tough substrates
evaporation in a vacuum is the dominant approach.
Accurate film thickness monitors are available enabling
calculated performance (for the materials used) to b
achieved. The choice of low refractive index materials
fl used in the films tends to limit the achievable perfor-
mance. To our knowledge, pieces 40" square have been
single layer vacuum coated and 40" x 20" pieces have
been tri-layer coated. During coating deposition it is
preferable to heat the substrate to give good adhesion,
thus the order of application of the rear projection
screen making processes must be carefully considered.
rl The use of vacuum deposited coatings with a flexible
plastic substrate may not be practical due to the heating
required.
Other approaches to the formation of thin films are
possible such as chemical reaction in a vapor or liquid
or anodization. Some of these methods may be feasible
for use with large plastic substrates depending, among
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other factors, on the precision of control available.
The second approach to reduce surface reflections is
to provide a gradual change of refractive index between
air and the substrate. This change should extend over
at least half a wavelength thickness. This scheme is
wideband and insensitive to angle of incidence and can
be implemented at microwave frequencies but satisfactory
optical material is not available.
D. LENTICULAR SCREENS
Lenticular, or lens-like, screens operate by refraction
of light rather than by light scattering. One such
screen consists of a plane matrix of very small lenses.
Each small lens acts as an image transfer element, tak--
ing a small element of an image which is projected on
the screen and transmitting and spreading the light from
the image element over the viewing field. The size of
the individual lehticules must be kept small if good
resolution properties are to be obtained.
An ideal rear projection screen, for most applications,
would have 100% transmission efficiency, constant
brightness within a specified range of viewing angles,
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and zero diffuse reflectance. The impossibility of
obtaining a scattering screen which simultaneously
satisfies these requirements has been established.
Lenticular screens, however, are not subject to the
same trade-offs and limitations as scattering screens,
and properly designed lenticular screens can conceiv-
ably approach these ideal requirements. Provided that
care is taken to avoid total internal reflection of
projector light and that the lenticules are close-
packed with no void areas in between, the efficiency
of lenticular screens is limited only by surface re-
flection losses. Ambient light sensitivity can be kept
small by designing the screen to transmit or absorb
flambient light. The large range of angles at which
ambient light strikes all points of the screen leads to
the use of an absorbing mask on the viewing side. All
the projector light is focused through small openings
in the mask.
By the use /of an aspheric shape for th,e individual len-
ticules, screens exhibiting constant brightness over a
specified range of viewing angles are possible, without
a sacrifice in efficiency. Spherical lenticules will
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give an approximation to constant brightness at smaller
viewing angles. The only mechanism for color distor-
tion in lenticular screens is dispersion, which is a
small effect compared to the wavelength dependence
inherent in scattering screens.
The major problem in the development of practical len-
ticular screens is fabrication. The periphery of the
individual lenticules must have a shape which allows
close-packing with no void areas; e.g. triangular,
rectangular, hexagonal, etc. The brightness uniformity
of lenticular screens is dependent on lenticule curva-
ture, so it is desirable that this curvature should be
controllable. Workable masking techniques are needed
in order to obtain superior ambient light sensitivity .
characteristics. All of these problems are made more
complex by the requirement of small close-packed lenti-
cules, preferably less than 20 microns in diameter, to
meet resolution requirements.
Based on the preceding discussion; the following pro-
gram for development of lenticular screens is proposed:
\ .
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1. Seek configurations which will allow the realization
of the conceptual advantages. These configurations
will be analyzed to determine the screen properties
expected.
2. Investigate promising materials and techniques
applicable to the fabrication and masking of lenti-
cular screens.
3. Full size, screens will be assembled from, smaller
samples fabricated using workable techniques and
materials.
E. DISCRETE-PARTICLE SCREEN PERFORMANCE IMPROVEMENT
The disagreement between the measured and predicted per-
formance of discrete-particle screens which exists is
not well understood. It is important to improve this
type of screen because of the inherent high resolution
and potential fabrication advantages.
--- -
Theoretical limits of performance for volume scattering
materials have been calculated and substantiated by
measurements of bulk glass-ceramic materials. The dis-
crete-particle screens are of this same class and were
expected to demonstrate the same levels of performance;
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however, measured values of efficiency are only 60% of
?the theoretical values, and values of the diffuse
reflectance are too great by almost a factor of two.
This type of screen exhibits very high resolation;
e.g., MTF = .89 at 10 lines/mm and square bar targets
can be resolved with spatial frequencies in excess of
100 lines/mm.
Both theoretical and practical investigations will be
conducted in an attempt to improve the performance of
this type of screen.
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RECOMMENDED PROGRAM
The recommended schedule is shown in FIGURE 1. The schedule
is based on Corning's four-week accounting periods It will
be noticed that several activities will be simultaneous for
an appreciable portion of the program. This reflects the
custom optical services to be utilized and specialized
assistance from Departments of Corning other than the Elec-
tronic Research Laboratory. First priority has been given to
initiating the system studies, together with the investigation
of substrate darkening and reduction of surface reflections.
Once an activity has been initiated,action in one form or
another is expected until nearly the end of the program.
Two periods are allowed for sample screen fabrication and
final report writing at the end of the program.
Progress will be reported in period reports.
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Final Report
44
*1 Period equals 4 weeks.
Declassified in Part - Sanitized Copy Approved for Release 2012/09/06: CIA-RDP79B00873A001900010121-0
Declassified in Part - Sanitized Copy Approved for Release 2012/09/06: CIA-RDP79B00873A001900010121-0
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STAT
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VI. FACILITIES
The facilities available at the onset of the first contract
have been maintained intact and additions have been made.
A 300 square foot laboratory has been set up just for dis-
play screen ?research and equipped with the following new
instruments:
a goniophotometer
a modulation transfer function analyzer
a diffuse refiectometer
Declassified in Part - Sanitized Copy Approved for Release 2012/09/06: CIA-RDP79B00873A001900010121-0