FLY EYE INTEGRATOR POLARIZATION CONVERTER

BACKGROUND

Projection systems used for projecting an image on a screen can use multiple color light sources, such as light emitting diodes (LED's), with different colors to generate the illumination light. Several optical elements are disposed between the LED's and the image display unit to combine and transfer the light from the LED's to the image display unit. The image display unit can use various methods to impose an image on the light. For example, the image display unit may use polarization, as with transmissive or reflective liquid crystal displays.

Still other projection systems used for projecting an image on a screen can use white light configured to imagewise reflect from a digital micro-mirror (DMM) array, such as the array used in Texas Instruments' Digital Light Processor (DLP®) displays. In the DLP® display, individual mirrors within the digital micro-mirror array represent individual pixels of the projected image. A display pixel is illuminated when the corresponding mirror is tilted so that incident light is directed into the projected optical path. A rotating color wheel placed within the optical path is timed to the reflection of light from the digital micro-mirror array, so that the reflected white light is filtered to project the color corresponding to the pixel. The digital micro-mirror array is then switched to the next desired pixel color, and the process is continued at such a rapid rate that the entire projected display appears to be continuously illuminated. The digital micro-mirror projection system requires fewer pixelated array components, which can result in a smaller size projector.

Image brightness is an important parameter of a projection system. The brightness of color light sources and the efficiencies of collecting, combining, homogenizing and delivering the light to the image display unit all affect brightness. As the size of modern projector systems decreases, there is a need to maintain an adequate level of output brightness while at the same time keeping heat produced by the color light sources at a low level that can be dissipated in a small projector system. There is a need for a light combining system that combines multiple color lights with increased efficiency to provide a light output with an adequate level of brightness without excessive power consumption by light sources.

Such electronic projectors often include a device for optically homogenizing a beam of light in order to improve brightness and color uniformity for light projected on a screen. Two common devices are an integrating tunnel and a fly's eye homogenizer. Fly's eye homogenizers can be very compact, and for this reason is a commonly used device. Integrating tunnels can be more efficient at homogenization, but a hollow tunnel generally requires a length that is often 5 times the height or width, whichever is greater. Solid tunnels often are longer than hollow tunnels, due to the effects of refraction.

Pico and pocket projectors have limited available space for light integrators or homogenizers. However, efficient and uniform light output from the optical devices used in these projectors (such as color combiners and polarization converters) can require a compact and efficient integrator.

SUMMARY

The present disclosure relates generally to an optical element, a light projector that includes the optical element, and an image projector that includes the optical element. In particular, the optical element provides an improved uniformity of light by homogenizing the light with lenslet arrays, such as “fly-eye arrays” (FEA). In one aspect, the present disclosure provides an optical element that includes a first lenslet array having a first plurality of lenses disposed to accept an unpolarized light and output a convergent unpolarized light. The optical element further includes a polarization converter disposed to accept the convergent unpolarized light and output a convergent polarized light. The optical element still further includes a second lenslet array having a second plurality of lenses disposed to accept the convergent polarized light and output a divergent polarized light. An unpolarized light ray coincident with the optical axis of a first lens of the first plurality of lenses passes through the polarization converter and becomes a first polarized light ray and a second polarized light ray, and further the first polarized light ray is coincident with the optical axis of a second lens of the second plurality of lenses, and the second polarized light ray is coincident with the optical axis of a third lens of the second plurality of lenses.

In another aspect, the present disclosure provides a light projector that includes a first unpolarized light source and a second unpolarized light source, a color combiner disposed to output a combined unpolarized light from the first unpolarized light source and the second unpolarized light source, and an optical element. The optical element includes a first lenslet array having a first plurality of lenses disposed to accept the combined unpolarized light and output a convergent unpolarized light, a polarization converter disposed to accept the convergent unpolarized light and output a convergent polarized light, and a second lenslet array having a second plurality of lenses disposed to accept the convergent polarized light and output a divergent polarized light. An unpolarized light ray coincident with the optical axis of a first lens of the first plurality of lenses passes through the polarization converter and becomes a first polarized light ray and a second polarized light ray, and further the first polarized light ray is coincident with the optical axis of a second lens of the second plurality of lenses, and the second polarized light ray is coincident with the optical axis of a third lens of the second plurality of lenses.

In yet another aspect, the present disclosure provides an image projector that includes a first unpolarized light source and a second unpolarized light source, a color combiner disposed to output a combined unpolarized light from the first unpolarized light source and the second unpolarized light source, an optical element, a spatial light modulator disposed to impart an image to the divergent polarized light, and projection optics. The optical element includes a first lenslet array having a first plurality of lenses disposed to accept the combined unpolarized light and output a convergent unpolarized light, a polarization converter disposed to accept the convergent unpolarized light and output a convergent polarized light, and a second lenslet array having a second plurality of lenses disposed to accept the convergent polarized light and output a divergent polarized light. An unpolarized light ray coincident with the optical axis of a first lens of the first plurality of lenses passes through the polarization converter and becomes a first polarized light ray and a second polarized light ray, and further the first polarized light ray is coincident with the optical axis of a second lens of the second plurality of lenses, and the second polarized light ray is coincident with the optical axis of a third lens of the second plurality of lenses.

The above summary is not intended to describe each disclosed embodiment or every implementation of the present disclosure. The figures and the detailed description below more particularly exemplify illustrative embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

Throughout the specification reference is made to the appended drawings, where like reference numerals designate like elements, and wherein:

FIG. 1 shows a schematic diagram of an image projector;

FIG. 2 shows a cross-section schematic of an optical element;

FIG. 3 shows a cross-section schematic of an optical element;

FIG. 4 shows a cross-section schematic of an optical element; and

FIG. 5 shows a cross-section schematic of a polarization converter.

The figures are not necessarily to scale. Like numbers used in the figures refer to like components. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number.

DETAILED DESCRIPTION

This disclosure generally relates to image projectors, in particular image projectors improve the uniformity of light by homogenizing the light with lenslet arrays, such as “fly-eye arrays” (FEA). In one particular embodiment, an illuminator for an image projector includes a light source in which emitted unpolarized light is directed into an array of lenses that focus the light. The light can be focused in at least one axis, and the converging beams of light from the lenslet array are passed into a polarization converter. The polarization converter separates the light into two paths, one for each polarization state. The path length for each of the two polarization states are approximately equal, and the converging beams of light reach a focal point near a second array of lenses. The second array of lenses can cause the light beams to diverge, and the light beams are then directed for further processing, for example, by using a spatial light modulator to impart an image to the light beams, and projection optics to display the image on a screen.

In some cases, optical projectors use a non-polarized light source, such as a light emitting diode (LED) or a discharge light, a polarization selecting element, a first polarization spatial modulator, and a second polarization selecting element. Since the first polarization selecting element rejects 50% of the light emitted from the non-polarized light source, polarization-selective projectors can often have a lower efficiency than non-polarized devices.

One technique of increasing the efficiency of polarization-selective projectors is to add a polarization converter between the light source and the first polarization selecting element. Generally, there are two ways of designing a polarization converter used in the art. The first is to partially collimate the light emitting from the light source, pass the partially collimated beam of light through an array of lenses, and position an array of polarization converters at each focal point. The polarization converter typically has a polarizing beam splitter having polarization selective tilted film (for example MacNeille polarizer, a wire grid polarizer, or birefringent optical film polarizer), where the reflected polarization is reflected by a tilted mirror such that the reflected beam propagates parallel to the beam that is transmitted by the tilted polarization selective film. Either one or the other beams of polarized light is passed through half-wave retarders, such that both beams have the same polarization state.

Another technique of converting the unpolarized light beam to a light beam having a single polarization state is to pass the entire beam of light through a tilted polarization selector, and the split beams are conditioned by mirrors and half-wave retarders such that a single polarization state is emitted. Illuminating a polarization selective spatial light modulator directly with a polarization converter can result in illuminance and color non-uniformity.

In one particular embodiment, a polarization converter can incorporate a fly's eye array to homogenize the light in a projection system. The input side of the polarization converter includes one or more lenses to focus the incoming light. The output side of the polarization converter includes twice the number of lenses as on the input side, with each lens on the output side centered approximately at the focal point of a matching lens at the input side. The lenses can be cylindrical, bi-convex, spherical or aspherical. In some cases, spherical lenses may be preferred; however, in many cases cylindrical lenses may be used. The fly's eye integrator and polarization converter can significantly improve the illuminance and color uniformity of the projector.

The lenses and lenslet arrays may be placed adjacent to the polarization converter input and output surfaces or they may be bonded to the prisms. Alternatively, the lenses may be fabricated by microreplicating plastic lenses on a film, which can be cut, aligned, and bonded to the polarization converter. Another alternative is to mold one or both prisms with the lenses as single units out of glass or plastic, and bond those to the reflective polarizer, quarter wave, and mirror film. For those cases when a half-wave retarder is needed to convert one polarization state to another, the half-wave retarder can be bonded to either the output of the polarization converter, or to other optical elements such as the condenser lens or polarizing beam splitter (PBS).

The lenslet arrays used on the input and output faces of the polarization converter may be made from a single axis lens, such as a cylindrical lens or a lens with two axes of refraction, such as a spherical lens. The number of lenses on the input face may range from a single lens, a single dimensional array of lenses, to a two dimensional array of lenses.

In some cases, a folded fly eye array can homogenize the illuminating light. A folded fly-eye array can be formed with a first lenslet array, a folding mirror, and a second lenslet array, where the lenses making up the second lenslet array are approximately at the focal point of the lenses making up the first lenslet array.

FIG. 1 shows a schematic diagram of an image projector 100, according to one aspect of the disclosure. Image projector 100 includes a color combiner module 110 that is capable of injecting a combined light output 124 into a homogenizing polarization converter module 130 where the combined light output 124 becomes converted to a homogenized polarized light 145 that exits the homogenizing polarization converter module 130 and enters an image generator module 150. The image generator module 150 outputs an imaged light 165 that enters a projection module 170 where the imaged light 165 becomes a projected imaged light 180.

In one aspect, color combiner module 110 includes different wavelength spectrum input light sources 112, 114, and 116 that are input through collimating optics 118 to color combiner 120. The color combiner 120 produces a combined light output 124 that includes the different wavelength spectrum lights. Color combiner modules 110 that are suitable for use in the present disclosure include those described, for example, in PCT Patent Publication Nos. WO2009/085856 entitled “Light Combiner”, WO2009/086310 entitled “Light Combiner”, WO2009/139798 entitled “Optical Element and Color Combiner”, WO2009/139799 entitled “Optical Element and Color Combiner”; and also in co-pending PCT Patent Application Nos. US2009/062939 entitled “Polarization Converting Color Combiner”, US2009/063779 entitled “High Durability Color Combiner”, US2009/064927 entitled “Color Combiner”, and US2009/064931 entitled “Polarization Converting Color Combiner”.

In one aspect, the received input light sources 112, 114, 116, are unpolarized, and the combined light output 124 is also unpolarized. The combined light output 124 can be a polychromatic combined light that comprises more than one wavelength spectrum of light. The combined light output 124 can be a time sequenced output of each of the received lights. In one aspect, each of the different wavelength spectra of light corresponds to a different color light (for example red, green and blue), and the combined light output is white light, or a time sequenced red, green and blue light. For purposes of the description provided herein, “color light” and “wavelength spectrum light” are both intended to mean light having a wavelength spectrum range which may be correlated to a specific color if visible to the human eye. The more general term “wavelength spectrum light” refers to both visible and other wavelength spectrums of light including, for example, infrared light.

According to one aspect, each input light source (112, 114, 116) comprises one or more light emitting diodes (LED's). Various light sources can be used such as lasers, laser diodes, organic LED's (OLED's), and non solid state light sources such as ultra high pressure (UHP), halogen or xenon lamps with appropriate collectors or reflectors. Light sources, light collimators, lenses, and light integrators useful in the present invention are further described, for example, in Published U.S. Patent Application No. US 2008/0285129, the disclosure of which is herein included in its entirety.

In one aspect, homogenizing polarization converter module 130 includes a polarization converter 140 that is capable of converting unpolarized combined light output 124 into homogenized polarized light 145. Homogenizing polarization converter module 130 further can include a first plurality of lenses 101 and a second plurality of lenses 102, both described elsewhere, that can homogenize and improve the uniformity of the combined light output 124 that exits the homogenizing polarization converter module 130 as homogenized polarized light 145.

In one aspect, image generator module 150 includes a polarizing beam splitter (PBS) 156, representative imaging optics 152, 154, and a spatial light modulator 158 that cooperate to convert the homogenized polarized light 145 into an imaged light 165. Suitable spatial light modulators (that is, image generators) have been described previously, for example, in U.S. Pat. Nos. 7,362,507 (Duncan et al.), 7,529,029 (Duncan et al.); in U.S. Publication No. 2008-0285129-A1 (Magarill et al.); and also in PCT Publication No. WO2007/016015 (Duncan et al.). In one particular embodiment, homogenized polarized light 145 is a divergent light originating from each lens of the FEA. After passing through imaging optics 152, 154 and PBS 156, homogenized polarized light 145 becomes imaging light 160 that uniformly illuminates the spatial light modulator. In one particular embodiment, each of the divergent light ray bundles from each of the lenses in the FEA illuminates a major portion of the spatial light modulator 158 so that the individual divergent ray bundles overlap each other.

In one aspect, projection module 170 includes representative projection optics 172, 174, 176, that can be used to project imaged light 165 as projected light 180. Suitable projection optics 172, 174, 176 have been described previously, and are well known to those of skill in the art.

FIG. 2 shows a side-view schematic of an optical element 200, according to one aspect of the disclosure. Optical element 200 can be used as the homogenizing polarization converter module 130 in the image projector 100 as shown in FIG. 1. Optical element 200 includes a first lenslet array 210, a polarization converter 220, and a second lenslet array 230. Each of the first lenslet array 210 and the second lenslet array 230 can be referred to as a “Fly-Eye Array”, or FEA, as known in the art. In some cases, each of the first lenslet array 210 and the second lenslet array 230 can include a converging (that is, positive) power. An unpolarized light 250, such as the unpolarized combined light output 124 shown in FIG. 1, enters the first lenslet array 210, passes through polarization converter 220, and exits second lenslet array 230 as divergent p-polarized light 260a and 260b. Generally, the path length of each polarization state of unpolarized combined light 250 is essentially the same through the optical element 200, as can be seen from the discussion that follows.

The first lenslet array 210 includes a representative first lens 212 of the plurality of lenses disposed to accept an unpolarized light 250 and output a convergent unpolarized light, such as shown by representative first unpolarized light 252, second unpolarized light 254, and third unpolarized light 256. In some cases, each lens of the first lenslet array 210 can be, for example, a cylindrical lens, and can be arranged in an array such that the long axis of the cylinder is perpendicular to the cross-section shown in FIG. 2. In some cases, each lens of the first lenslet array 210 can be, for example, a spherical lens, and can be arranged in a rectangular array. Each lens of the first lenslet array 210 has a first optical axis 211, and an exit surface 214 that is typically a planar surface. The first lenslet array 210 can be formed from a glass or a polymer, and can include a substrate coincident with exit surface 214, or can instead be a monolithic lenslet array formed from a single material.

In some cases, a high index glass can be used for the lenslet array. Also, high index glasses with lead tend to have low stress optical component (SOC) that can lead to a preferable low-birefringence. However, it can be difficult to mold small lens features into glass. As a result, polymeric materials are preferred for the lenslet array construction, including, for example, such polymers as polycarbonates (PC), cyclo-olefin polymers (COP), cyclo-olefin co-polymers (COC, and polymethylmethacrylates (PMMA). Exemplary polymeric materials include, for example, cyclo-olefinic polymer materials such as Zeonex® (for example, E48R, 330R, 340R, 480R, and the like, available from Zeon Chemicals L.P., Louisville, Ky.); cyclo-olefin co-polymers such as APL5514mL, APL5014DP and the like (available from Mitsui Chemicals, Inc. JP); polymethylmethacrylate (PMMA) materials such as WF100 (available from Mitsubishi Rayon Technologies, JP) and Acrypet® VH001 (available from Guangzhou Hongsu Trading Co., Guangdong, CN); and polycarbonate, polyester, or polyphenylene sulfide materials. Generally, a birefringence of less than 50 nm, or less than 30 nm, or even less than 20 nm is preferred (at a nominal wavelength of 550 nm). In some cases, a much wider range of materials can be used, for example, higher birefringence materials become acceptable, such as those having a birefringence of about 50 nm or more, when an FEA homogenizing component is placed after the illumination source and before the light is polarized, for example, as first lenslet array 210 is positioned in optical element 200.

The polarization converter 220 is disposed to accept the convergent unpolarized light, such as shown by representative first unpolarized light 252, second unpolarized light 254, and third unpolarized light 256, and output a convergent polarized light as described below. Polarization converter 220 includes a first prism 222 having first and second faces 223 and 228, a second prism 224 having third and fourth faces 221 and 227, and a third prism 226 having second face 228 (common with first prism 222), fifth face 225, and diagonal face 229. A reflective polarizer 240 is disposed on the diagonal between first and second prisms 222, 224.

The reflective polarizer 240 can be any known reflective polarizer such as a MacNeille polarizer, a wire grid polarizer, a multilayer optical film polarizer, or a circular polarizer such as a cholesteric liquid crystal polarizer. According to one embodiment, a multilayer optical film polarizer can be a preferred reflective polarizer. Generally, reflective polarizer 240 can be a Cartesian reflective polarizer or a non-Cartesian reflective polarizer. A non-Cartesian reflective polarizer can include multilayer inorganic films such as those produced by sequential deposition of inorganic dielectrics, such as a MacNeille polarizer. A Cartesian reflective polarizer has a polarization axis direction, and includes both wire-grid polarizers and polymeric multilayer optical films such as can be produced by extrusion and subsequent stretching of a multilayer polymeric laminate. In one embodiment, reflective polarizer 240 is aligned so that one polarization axis is parallel to a first polarization direction, and perpendicular to a second polarization direction. In one embodiment, the first polarization direction can be the s-polarization direction, and the second polarization direction can be the p-polarization direction.

A Cartesian reflective polarizer film provides the polarizing beam splitter with an ability to pass input light rays that are not fully collimated, and that are divergent or skewed from a central light beam axis. The Cartesian reflective polarizer film can comprise a polymeric multilayer optical film that comprises multiple layers of dielectric or polymeric material. Use of dielectric films can have the advantage of low attenuation of light and high efficiency in passing light. The multilayer optical film can comprise polymeric multilayer optical films such as those described in U.S. Pat. No. 5,962,114 (Jonza et al.) or U.S. Pat. No. 6,721,096 (Bruzzone et al.).

The polarization converter 220 further includes a polarization rotating reflector that includes a quarter-wave retarder 242 and a broadband mirror 244 disposed on fourth face 227. Polarization rotating reflectors are discussed elsewhere, for example, in PCT Publication No. WO2009/085856 (English et al.). The polarization rotating reflector reverses the propagation direction of the light and alters the magnitude of the polarization components, depending of the components and their orientation in the polarization rotating reflector. The polarization rotating reflector generally includes a reflector and a retarder. In one embodiment, the reflector can be a broadband mirror that blocks the transmission of light by reflection. The retarder can provide any desired retardation, such as an eighth-wave retarder, a quarter-wave retarder, and the like. In embodiments described herein, there can be an advantage to using a quarter-wave retarder and an associated reflector. Linearly polarized light is changed to circularly polarized light as it passes through a quarter-wave retarder aligned at an angle of 45° to the axis of light polarization. Reflections from the reflective polarizer and quarter-wave retarder/reflectors result in efficient light output from the polarization converter. In contrast, linearly polarized light is changed to a polarization state partway between s-polarization and p-polarization (either elliptical or linear) as it passes through other retarders and orientations, and can result in a lower efficiency of the polarization converter.

Preferably, quarter-wave retarder 242 includes a quarter-wave polarization direction aligned at +/−45° to the first polarization direction. In some embodiments, the quarter-wave polarization direction can be aligned at any degree orientation to first polarization direction, for example from 90° in a counter-clockwise direction to 90° in a clockwise direction. It can be advantageous to orient the retarder at approximately +/−45° as described, since circularly polarized light results when linearly polarized light passes through a quarter-wave retarder so aligned to the polarization direction. Other orientations of quarter-wave retarders can result in s-polarized light not being fully transformed to p-polarized light, and p-polarized light not being fully transformed to s-polarized light, upon reflection from the mirrors, resulting in reduced efficiency as described elsewhere.

A second broadband mirror 246 is disposed adjacent the diagonal 229 of third prism 226. The components of the polarization converter including prisms, reflective polarizers, quarter-wave retarders, mirrors and any other components can be bonded together by a suitable optical adhesive. The optical adhesive used to bond the components together can have a lower index of refraction than the index of refraction of the prisms used in the light combiner. A polarization converter that is fully bonded together offers advantages including alignment stability during assembly, handling and use.

According to one particular embodiment, the prism faces 221, 223, 225, 227, 229 are polished external surfaces that are in contact with a material having an index of refraction “n₁” that is less than the index of refraction “n₂” of prisms 222, 224, and 226. According to another embodiment, all of the external faces of the polarization converter 220 (including end faces, not shown) are polished faces that provide TIR of oblique light rays within polarization converter 220. The polished external surfaces are in contact with a material having an index of refraction “n₁” that is less than the index of refraction “n₂” of prisms 222, 224, and 226. TIR improves light utilization in polarization converter 220, particularly when the light directed into the polarization converter 220 is not collimated along a central axis, that is the incoming light is either convergent or divergent.

The second lenslet array 230 includes a representative second lens 232a and a third lens 232b disposed to accept convergent polarized light such as shown by representative first through sixth convergent p-polarized light 262-267, and output a divergent p-polarized light 260a and 260b. In some cases, each lens of the second lenslet array 230 can be, for example, a cylindrical lens, and can be arranged in an array such that the long axis of the cylinder is perpendicular to the cross-section shown in FIG. 2. In some cases, each lens of the second lenslet array 230 can be, for example, a spherical lens, and can be arranged in a rectangular array. Each lens of the second lenslet array 230 has a second optical axis 231, and an entrance surface 234 that is typically a planar surface. The second lenslet array 230 can be formed from a glass or a polymer, and can include a substrate coincident with entrance surface 234, or can instead be a monolithic lenslet array formed from a single material.

Unpolarized light rays 250 coincident with the first optical axis 211 of the first lens 212 becomes first convergent unpolarized light ray 252, enters polarization converter 220 through third face 221 of second prism 224, and intercepts reflective polarizer 240 where it is split into first p-polarized convergent light ray 262 and first s-polarized convergent light ray 253. In a similar manner, another of the unpolarized light rays 250 entering first lens 212 at a position separated from the first optical axis 211 becomes second convergent unpolarized light ray 254, and is split into second p-polarized convergent light ray 264 and second s-polarized convergent light ray 255. In yet another similar manner, another of the unpolarized light rays 250 entering first lens 212 at a second position separated from the first optical axis 211 becomes third convergent unpolarized light ray 256, and is split into third p-polarized convergent light ray 266 and third s-polarized convergent light ray 257.

First, second, and third p-polarized convergent light rays 262, 264, 266 pass through reflective polarizer 240, reflect from broadband mirror 246, and exit polarization converter 220 through fifth face 225 of third prism 226. The focus of the first, second, and third p-polarized convergent light rays 262, 264, 266 is positioned near the second lenslet array 230 such that the first unpolarized light ray 252 that was coincident with the first optical axis 211 of the first lens 212 becomes first p-polarized convergent light ray 262 that is coincident with the second optical axis 231 of the second lens 232b. Generally, the focal point of each lens (for example, first lens 212) of the first lenslet array 210 is positioned at the first principle plane of each lens (for example, second lens 232b) of the second lenslet array 230. Collectively, the representative first, second, and third p-polarized convergent light rays 262, 264, 266 become first p-polarized divergent light 260b as they pass through second lens 232b of second lenslet array 230.

First, second, and third s-polarized convergent light rays 253, 255, 257 reflect from reflective polarizer 240, exit second prism through fourth face 227, change to circular polarized convergent light as they pass through quarter-wave retarder 242, reflect from broadband mirror 244 changing the direction of circular polarization, and become fourth, fifth, and sixth p-polarized convergent light 263, 265, 267, as they pass again through quarter-wave retarder 242. Fourth, fifth, and sixth p-polarized convergent light 263, 265, 267 pass through reflective polarizer 240, exit polarization converter 220 through first face 223 of first prism 222. The focus of the fourth, fifth, and sixth p-polarized convergent light rays 263, 265, 267 is positioned near the second lenslet array 230 such that the first unpolarized light ray 252 that was coincident with the first optical axis 211 of the first lens 212 becomes fourth p-polarized convergent light ray 263 that is coincident with the second optical axis 231 of a third lens 232a of the second lenslet array 230. Generally, the focal point of each lens (for example, first lens 212) of the first lenslet array 210 is positioned at the first principle plane of each lens (for example, third lens 232a) of the second lenslet array 230. Collectively, the representative fourth, fifth, and sixth p-polarized convergent light rays 263, 265, 267, become second p-polarized divergent light 260a as they pass through third lens 232a of second lenslet array 230. P-polarized divergent light 260a and 260b pass through the remaining portions of the projection system described in FIG. 1, with an improved uniformity.

In some cases, the quarter-wave retarder 242 can instead be disposed adjacent reflective polarizer 240, between broadband mirror 244 and reflective polarizer 240 (not shown), and a similar optical path can be traced through the polarization converter 220, as known to one of skill in the art. In some cases, the polarization rotating reflector that includes the quarter-wave retarder 242 and broadband mirror 244 can instead be disposed on the third face 221, and the unpolarized input light rays 250 can enter polarization converter 220 through fourth face 227, and a similar optical path can be traced through the polarization converter 220, as known to one of skill in the art.

In one particular embodiment, minimizing the amount of birefringent effects that can impact a beam of light traversing a Fly's Eye's Array (FEA) includes selection of an FEA material that has a low stress optical coefficient (SOC), and is thin. The low SOC manifests as low induced birefringence in the substrate of the FEA after both surfaces of the substrate have been structured/molded into matching lenslet arrays. A second aspect to achieving low birefringence is to reduce the optical path in the substrate material. This requires a short focal length design for the lenslets. The focal point of the first lenslet array is cast onto the principal plane of the second lenslet array. The short focal length drives a small radius of curvature for each lenslet element. As a result, the lateral size of each lenslet typically is reduced, in order to maintain the aperture of each lenslet element (that is, no flat region of the array, without power). Therefore, the resultant number of lenslets per array is increased, which can improve beam homogenization.

Having a small lenslet lateral size requires a high precision in the registration of the optical axis of each lenslet element in the first lenslet array to the corresponding lenslet optical axis in the second lenslet array. In one particular embodiment, for example, a FEA used in an LED illuminator can have an approximately 0.6 mm×0.9 mm lenslet aperture and with typical mechanical positional tolerances of 30-50 um, the light crosstalk from the misalignment will be severe. The need for a low birefringent FEA element drives small and thin lenslet element design. A small lenslet element drives the need for a monolithic FEA fabrication for maintaining the required alignment precision. A thin lenslet substrate ensures little birefringence for the same amount of stressed induced in the substrates.

FIG. 3 shows a side-view schematic of an optical element 300, according to one aspect of the disclosure. Optical element 300 can be used as the homogenizing polarization converter module 130 in the image projector 100 as shown in FIG. 1. Optical element 300 includes a first lenslet array 210, a polarization converter 220, and a second lenslet array 230. Each of the elements 210-263 shown in FIG. 3 correspond to like-numbered elements 210-263 shown in FIG. 2, which have been described previously. In FIG. 3, first lenslet array 210 is positioned immediately adjacent second prism 224, such that exit surface 214 of first lenslet array 210 and third face 221 of second prism 224 are coincident. In a similar manner, second lenslet array 230 is positioned immediately adjacent first prism 222, such that planar surface 234 of second lenslet array 230 and first face 223 of second prism 224 are coincident (additionally, planar surface 234 of second lenslet array 230 and fifth face 225 of third prism 226 are also coincident).

In one particular embodiment, first lenslet array 210 and second lenslet array 230 can be adhered to their respective prism faces using an optical adhesive, as known in the art. In one particular embodiment, first lenslet array 210 and second lenslet array 230 can be directly molded onto their respective prism faces, for example, by using a mold to form the prisms simultaneously with the respective lenslet array; by using a mold to form the lenslet array onto the already formed prisms, such as with a thermoplastic or thermoset polymer; or by thermally embossing a lenslet array onto a formed prism; or the like.

A single unpolarized light ray 252 coincident with the first optical axis 211 is shown to be traced through the polarization converter 220, in FIG. 3. It will be appreciated by one of skill in the art that the various convergent and divergent light rays correspondingly drawn in FIG. 2, pass in a similar manner through the embodiment shown in FIG. 3. However, since the separation between the lenslet arrays and their respective prism faces has changed from that shown in FIG. 2, the focal length of each lens may also be different, as known to one of skill in the art. As such, an unpolarized light 350 entering the optical element 300 leaves as a first p-polarized divergent light 360b and a second p-polarized divergent light 360a. It is to be understood that either one or both of the first and second lenslet arrays 210, 230, can be immediately adjacent the respective prism face.

FIG. 4 shows a side-view schematic of an optical element 300, according to one aspect of the disclosure. Optical element 400 can be used as the homogenizing polarization converter module 130 in the image projector 100 as shown in FIG. 1. Optical element 400 includes a first lenslet array 410, a polarization converter 420, and a second lenslet array 430. Each of the elements 410-446 shown in FIG. 4 correspond to like-numbered elements 210-246 shown in FIG. 2, which have been described previously. For example, third prism 426 of FIG. 4 corresponds to third prism 226 of FIG. 2, and so on. In FIG. 4, the relative position of reflective polarizer 440 has changed from the position of reflective polarizer 240 in FIG. 2, and as a result, the path length of each component of the unpolarized input light 450 is different in the configuration shown in FIG. 4, as can be seen in the figure. Generally, the path lengths of each polarization component are preferably the same; however, the optical element 400 will function as an alternate embodiment of a homogenizing polarization converter.

Unpolarized light rays 450 coincident with the first optical axis 411 of the first lens 412 becomes first convergent unpolarized light ray 452, enters polarization converter 420 through third prism face 421 of second prism 424, and intercepts reflective polarizer 440 where it is split into first p-polarized convergent light ray 462 and first s-polarized convergent light ray 453. In a similar manner, another of the unpolarized light rays 450 entering first lens 412 at a position separated from the first optical axis 411 becomes second convergent unpolarized light ray 454, and is split into second p-polarized convergent light ray 464 and second s-polarized convergent light ray 455. In yet another similar manner, another of the unpolarized light rays 450 entering first lens 412 at a second position separated from the first optical axis 411 becomes third convergent unpolarized light ray 456, and is split into third p-polarized convergent light ray 466 and third s-polarized convergent light ray 457.

First, second, and third p-polarized convergent light rays 462, 464, 466 pass through reflective polarizer 440, reflect from broadband mirror 446, and exit polarization converter 420 through fifth prism face 425 of third prism 426. The first, second, and third p-polarized convergent light rays 462, 464, 466 then pass through a half-wave retarder 448 and change to fourth, fifth, and sixth s-polarized convergent light rays 472, 474, 476. The focus of the fourth, fifth, and sixth s-polarized convergent light rays 472, 474, 476 is positioned near the second lenslet array 430 such that the first unpolarized light ray 452 that was coincident with the first optical axis 411 of the first lens 412 becomes fourth s-polarized convergent light ray 472 that is coincident with the second optical axis 431 of the second lens 432b. Generally, the focal point of each lens (for example, first lens 412) of the first lenslet array 410 is positioned at the first principle plane of each lens (for example, second lens 432b) of the second lenslet array 430. Collectively, the representative fourth, fifth, and sixth s-polarized convergent light rays 472, 474, 476 become first s-polarized divergent light 460b as they pass through second lens 432b of second lenslet array 430.

First, second, and third s-polarized convergent light rays 453, 455, 457 reflect from reflective polarizer 440, and exits second prism 424 through third prism face 423. The focus of the first, second, and third s-polarized convergent light rays 453, 455, 457 is positioned near the second lenslet array 430 such that the first unpolarized light ray 452 that was coincident with the first optical axis 411 of the first lens 412 becomes third s-polarized convergent light ray 453 that is coincident with the second optical axis 431 of a third lens 432a of the second lenslet array 430. Generally, the focal point of each lens (for example, first lens 412) of the first lenslet array 410 is positioned at the first principle plane of each lens (for example, third lens 432a) of the second lenslet array 430. Collectively, the representative first, second, and third s-polarized convergent light rays 453, 455, 457 become second s-polarized divergent light 460a as they pass through third lens 432a of second lenslet array 430.

It is to be understood that each of the first lenslet array 410 and the second lenslet array 430 can be positioned immediately adjacent to the respective prism faces in a manner similar to that shown in FIG. 3 (or alternately, immediately adjacent to a half-wave retarder disposed between a prism face and the second lenslet array 430, as shown in FIG. 4).

FIG. 5 shows a cross-section schematic of a polarization converter 520 according to one particular embodiment of the disclosure. Polarization converter 520 can be used in place of any of the already described polarization converters, for example, polarization converter 220 in optical element 200; polarization converter 420 in optical element 400; and also as described in optical element 300, where the polarization converter can include integral lenslet arrays. For brevity, the lenslet arrays have been removed from FIG. 5, and only the path of light through the polarization converter 520 will be described. It is to be understood, however, that the polarization converter module 130 of FIG. 1 includes polarization converter 520 and any associated lenslet array, similar to those described in FIGS. 2-4.

Each of the elements 520-546 shown in FIG. 5 correspond to like-numbered elements 220-246 shown in FIG. 2, which have been described previously. For example, third prism 526 of FIG. 5 corresponds to third prism 226 of FIG. 2, and so on. In FIG. 5, the relative position of reflective polarizer 540 has changed from the position of reflective polarizer 240 in FIG. 2, and as a result, the path length of each component of the unpolarized input light 552 is different in the configuration shown in FIG. 5, as can be seen in the figure. Generally, the path lengths of each polarization component are preferably the same; however, the polarization converter 520 will function as an alternate embodiment of a homogenizing polarization converter.

In one particular embodiment shown in FIG. 5, the second prism 524 has an optional elongated portion “P” extending the length of prism face 523. The extended length of prism face 523 can serve to increase the path length of the unpolarized input light 552, and as a result, the homogenization of the unpolarized input light 552 as described, for example, in co-pending U.S. Patent Application No. 61/292,574, entitled “Compact Optical Integrator” (Attorney Docket No. 65902US002) filed on Jan. 6, 2010.

In one particular embodiment, the polarization converter 520 includes a half-wave retarder 548 disposed between first prism 522 and third prism 526 as shown in FIG. 5. In one particular embodiment, the half-wave retarder 548 can instead be disposed adjacent the prism face 525, in a manner similar to the half-wave retarder 448 shown in FIG. 4. In some cases, the half-wave retarder can be placed anywhere within the optical path of the light transmitted through the reflective polarizer 540, such that the polarization state of the transmitted light is changed to the polarization state of the reflected light. In one particular embodiment, the half-wave retarder can be inserted adjacent to any of the prism faces 523, 540, 548, 525, and 529.

Central unpolarized light beam 552 enters first prism face 521 and intercepts reflective polarizer 540 where it is split into transmitted p-polarized light beam 562 and reflected first s-polarized light beam 553. Reflected first s-polarized light beam 553 then exits polarization converter 520 through second prism face 523. Transmitted p-polarized light beam 562 exits second prism 522, passes through half-wave retarder 548 changing to second s-polarized light beam 572, reflects from broadband reflector 546, and exits polarization converter 520 through fifth prism face 525.

Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims are to be understood as being modified by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein.

All references and publications cited herein are expressly incorporated herein by reference in their entirety into this disclosure, except to the extent they may directly contradict this disclosure. Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this disclosure be limited only by the claims and the equivalents thereof.

FLY EYE INTEGRATOR POLARIZATION CONVERTER

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