Post-objective scanning beam systems

Abstract

Scanning beam systems, apparatus and techniques in optical post-objective designs with two beam scanners for display and other applications.

Description

BACKGROUND

This application relates to scanning-beam systems for producing optical patterns in various applications.

Scanning beam systems can be used to project one or more scanned beams on a surface to produce optical patterns. Many laser printing systems use a scanning laser beam to print on a printing surface of a printing medium (e.g., paper). Some display systems use 2-dimensionally scanned light to produce images on a screen.

As an example, many display systems such as laser display systems use a polygon scanner with multiple reflective facets to provide horizontal scanning and a vertical scanning mirror such as a galvo-driven mirror to provide vertical scanning. In operation, one facet of the polygon scanner scans one horizontal line as the polygon scanner spins to change the orientation and position of the facet and the next facet scans the next horizontal line. The horizontal scanning and the vertical scanning are synchronized to each other to project images on the screen.

Some scanning-beam systems such as scanning-beam display systems use a pre-objective optical design where a scan lens is placed in the optical path downstream from the polygon scanner and the vertical scanner to focus a scanning beam onto a target surface, e.g., a screen. Because the scan lens is positioned downstream from the polygon scanner and the vertical scanner, the beam entering the scan lens is scanned along the vertical and horizontal directions. Therefore, the scan lens is designed to focus the 2-dimensionally scanned beam onto the target surface.

SUMMARY

The specification of this application describes, among others, scanning beam systems, apparatus and techniques in optical post-objective designs with two beam scanners for display and other applications.

In one implementation, a scanning beam system includes a light source operable to produce a beam of light; a first beam scanner to scan the beam of light along a first direction; a second beam scanner to scan the beam of light received from the first beam scanner along a second direction different from the first direction; and a scan lens placed in an optical path of the beam of light between the first and the second beam scanners to direct the beam of light from the first beam scanner along a line on the second beam scanner and to focus the beam of light onto a surface away from the second beam scanner. The system may include a beam focusing element placed in an optical path of the beam of light to adjust a focus of the beam of light; and an actuator coupled to the beam focusing element to adjust a position of the beam focusing element, in response to a control signal, to adjust the focus in synchronization with scanning of the second beam scanner.

In another implementation, a scanning beam system includes an optical module operable to produce a scanning beam of excitation light having optical pulses that can be used to carry image information; and a fluorescent screen which absorbs the excitation light and emits visible fluorescent light to produce images carried by the scanning beam. The optical module includes a light source to produce the beam of excitation light; a horizontal polygon scanner to scan the beam of excitation light along a first direction; a vertical scanner to scan the beam of excitation light from the polygon along a second direction different from the first direction; and a 1-dimensional scan lens placed between the polygon scanner and the vertical scanner to direct the beam of excitation light from the polygon scanner along a line on the vertical scanner and to focus the beam of excitation light onto the screen.

In another implementation, a scanning beam system includes a light source to produce a beam of light having optical pulses that carry image information; a horizontal polygon scanner to scan the beam along a first direction at a first scanning rate; a vertical scanner to scan the beam from the polygon along a second direction different from the first direction at a second scanning rate less than the first scanning rate; a 1-dimension scan lens placed between the polygon scanner and the vertical scanner to direct the beam from the polygon scanner along a line on the vertical scanner and to focus the beam onto a reference surface; a beam focusing element placed between the light source and the horizontal polygon scanner to adjust a focus of the beam on the reference surface; and an actuator coupled to the beam focusing element to adjust a position of the beam focusing element, in response to a control signal, to adjust the focus in synchronization with a scanning position of the vertical scanner.

In yet another implementation, a method for scanning a beam along two directions on a target surface includes scanning the beam with a first scanner to scan the beam along a first direction at a first scanning rate; directing the beam out of the first scanner into a second scanner to scan the beam along a second direction different from the first direction at a second scanning rate less than the first scanning rate; using a 1-dimension scan lens placed between the first and the second scanners to focus the beam onto the target surface; and controlling a focus of the beam in synchronization with a scanning position of the second scanner to control focusing of the beam on the target surface.

In yet another implementation, a scanning beam display system is disclosed to include light source that produces a beam of light; a first beam scanner located in a plane to scan the beam of light along a first direction; a second beam scanner located in the plane to scan the beam of light received from the first beam scanner along a second direction different from the first direction; and a screen having a display surface that is substantially perpendicular to and is located entirely on one side of the plane in which the first and second beam scanners are located. The screen is positioned to have one edge close to the second beam scanner which scans the beam of light in beam directions that are not directed to the screen. An optical reflector is located on the side of the plane where the screen is located and is positioned away from the screen and the optical reflector is oriented to reflect the beam of light from the second beam scanner onto the screen along a folded optical path to scan the beam of light along the first and the second directions on the screen.

These and other implementations are described in detail in the drawings, the detailed description and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an example implementation of a post-objective scanning system.

FIGS. 2A and 2B show two examples of a laser source for modulating information onto a scanning beam in the system of FIG. 1.

FIG. 3A illustrates an example of a fluorescent screen having color phosphor stripes that can be used in a post-objective scanning beam display system.

FIG. 3B shows an exemplary design of the screen in FIG. 3A.

FIG. 3C shows the operation of the screen in a view along the direction perpendicular to the surface of the screen in FIG. 3A.

FIG. 4 shows another exemplary design of the screen in FIG. 3A.

FIG. 5 shows an example of a post-objective scanning beam display system based on the system design in FIG. 1.

FIGS. 6A, 6B and 6C illustrate a specific example of the post-objective design of the beam scanning module in FIG. 5.

FIGS. 7, 8 and 9 show various image effects on the screen of a post-objective scanning system.

FIG. 10 shows an example of a post-objective scanning display based on a folded optical rear projection design.

FIGS. 11-13 show examples of the vertical scanner for post-objective scanning systems.

FIGS. 14, 15 and 16 illustrate examples associated with a different post-objective scanning system.

DETAILED DESCRIPTION

Examples of post-objective scanning-beam systems described in this application use a vertical scanner with an optical reflector and a spinning horizontal polygon scanner with reflective facets to provide the 2-dimensional scanning of one or more scanning beams onto a target screen. A beam can be first directed to a first scanner of the vertical scanner and the polygon scanner to scan along a first direction and then directed through a scan lens located between the vertical scanner and the polygon scanner. After exiting the scan lens, the beam is scanned along the first direction and is directed to the second scanner of the vertical scanner and the polygon scanner to scan along a second, different direction (e.g., orthogonal to the first direction). The output of the second scanner is a scanning beam that is scanned along both the first and the second directions.

FIG. 1 shows an example implementation of a post-objective scanning system. A laser source 110 is provided to produce at least one laser beam 112. Depending on the specific applications, this single beam can be a beam of a particular wavelength, e.g., a visible color, UV light or other wavelengths. In some applications, multiple beams 112 may be generated from the laser source 110 and are scanned. The different beams 112 may be of different wavelengths, e.g., red, green and blue colors in the visible range, or of the same or similar wavelengths, e.g., UV light. In this example, the first scanner of the two scanners is a polygon scanner 140. The beam 112 is scanned along the first direction (e.g., the horizontal direction) by the polygon scanner 140 as a 1-D scanning beam 114. The second scanner downstream from the polygon scanner 140 is a vertical scanner 150, e.g., a galvo mirror constructed by engaging a mirror to a galvanometer and operates to scan the horizontally scanning beam 114 along the vertical direction as a 2-D scanning beam 116 to a target surface 101, e.g., a screen. A scan lens 120 is placed between the two scanners 140 and 150.

In this post-objective design, the scan lens 120 can be structured to have high optical performance in focusing the 1-D scanning beam 114 along the scanning direction of the first scanner 140 only. Hence, such a scan lens does need to exhibit high optical performance along the second scanning direction (i.e., the vertical direction in this example) because the beam 114 is not scanned along the second scanning direction at the position of the scan lens 120. Therefore, the scan lens 120 can be a 1-D scan lens, e.g., a 1-D f theta lens. High-cost and complex 2-D lenses can be avoided in implementing the system of FIG. 1. Due to the design of the scan lens 120, the focusing of the beam 116 on the target surface 101 does not change with the horizontal scanning.

In another aspect, the vertical scanner 150 in FIG. 1 scans at a much smaller rate as the second scanner than the scan rate of the first horizontal scanner 140 and thus a focusing variation caused by the vertical scanning on the target surface 101 varies with time at the slower vertical scanning rate. This allows a focusing adjustment mechanism to be implemented in the system of FIG. 1 with the lower limit of a response speed at the slower vertical scanning rate rather than the high horizontal scanning rate. In practical devices, this particular arrangement of two scanners 140 and 150 allows easy implementation of the dynamic focusing adjustment to maintain the proper focusing of the 2-D scanning beam on the target surface as the vertical scanner 150 scans along the vertical direction.

The target surface 101 in FIG. 1 is a surface of a target device 102. The device 102 can be in various forms depending on the applications of the system in FIG. 1. For example, in display applications, the target device 102 can be a screen on which images carried by the scanning beam 116 are displayed in a way visible to a viewer. The beam 112 incident to the first scanner 140 is optically modulated to carry the images to be displayed on the screen 102.

FIGS. 2A and 2B show two optical modulation designs that can be used to modulate the beam 112 to carry images or other information. In FIG. 2A, a laser 210 such as a diode laser is directly modulated to produce a modulated beam 112 that carries the image signals, e.g., color image data in red, green and blue. The laser source 110 in this implementation includes a signal modulation controller 220 which modulates the laser 210 directly. For example, the signal modulation controller 220 can control the driving current of a laser diode as the laser 210. In FIG. 2B, a laser 230 is used to generate a CW unmodulated laser beam 232 and an optical modulator 240 is used to modulate the CW laser beam 232 with the image signals in red, green and blue and to produce the modulated beam 112. A signal modulation controller 250 is used to control the optical modulator 240. For example, an acousto-optic modulator or an electro-optic modulator may be used as the optical modulator 240.

The screen 102 can be passive screens and active screens. A passive screen does not emit light but makes light of the one or more scanning beams visible to a viewer by one or a combination of mechanisms, such as optical reflection, optical diffusion, optical scattering and optical diffraction. For example, a passive screen can reflect or scatter received scanning beam(s) to show images.

An active screen emits light by absorbing the one or more scanning beams and the emitted light forms part of or all of the light that forms the displayed images. Such an active screen may include one or more fluorescent materials to emit light under optical excitation of the one or more scanning beams received by the screen to produce images. The term “a fluorescent material” is used here to cover both fluorescent materials and phosphorescent materials. Screens with phosphor materials under excitation of one or more scanning excitation laser beams are described here as specific implementation examples of optically excited fluorescent or phosphorescent materials in various systems.

Various screen designs with fluorescent materials can be used. Screens with phosphor materials under excitation of one or more scanning excitation laser beams are described in detail and are used as specific implementation examples of optically excited fluorescent materials in various system and device examples in this application. In one implementation, for example, three different color phosphors that are optically excitable by the laser beam to respectively produce light in red, green, and blue colors suitable for forming color images can be formed on the screen as repetitive red, green and blue phosphor stripes in parallel. Various examples described in this application use screens with parallel color phosphor stripes for emitting light in red, green, and blue to illustrate various features of the laser-based displays. Phosphor materials are one type of fluorescent materials. Various described systems, devices and features in the examples that use phosphors as the fluorescent materials are applicable to displays with screens made of other optically excitable, light-emitting, non-phosphor fluorescent materials.

For example, quantum dot materials emit light under proper optical excitation and thus can be used as the fluorescent materials for systems and devices in this application. More specifically, semiconductor compounds such as, among others, CdSe and PbS, can be fabricated in form of particles with a diameter on the order of the exciton Bohr radius of the compounds as quantum dot materials to emit light. To produce light of different colors, different quantum dot materials with different energy band gap structures may be used to emit different colors under the same excitation light. Some quantum dots are between 2 and 10 nanometers in size and include approximately tens of atoms such between 10 to 50 atoms. Quantum dots may be dispersed and mixed in various materials to form liquid solutions, powders, jelly-like matrix materials and solids (e.g., solid solutions). Quantum dot films or film stripes may be formed on a substrate as a screen for a system or device in this application. In one implementation, for example, three different quantum dot materials can be designed and engineered to be optically excited by the scanning laser beam as the optical pump to produce light in red, green, and blue colors suitable for forming color images. Such quantum dots may be formed on the screen as pixel dots arranged in parallel lines (e.g., repetitive sequential red pixel dot line, green pixel dot line and blue pixel dot line).

Some implementations of post-objective scanning beam display systems described here use at least one scanning laser beam to excite color light-emitting materials deposited on a screen to produce color images. The scanning laser beam is modulated to carry images in red, green and blue colors or in other visible colors and is controlled in such a way that the laser beam excites the color light-emitting materials in red, green and blue colors with images in red, green and blue colors, respectively. Hence, the scanning laser beam carries the images but does not directly produce the visible light seen by a viewer. Instead, the color light-emitting fluorescent materials on the screen absorb the energy of the scanning laser beam and emit visible light in red, green and blue or other colors to generate actual color images seen by the viewer.

Laser excitation of the fluorescent materials using one or more laser beams with energy sufficient to cause the fluorescent materials to emit light or to luminesce is one of various forms of optical excitation. In other implementations, the optical excitation may be generated by a non-laser light source that is sufficiently energetic to excite the fluorescent materials used in the screen. Examples of non-laser excitation light sources include various light-emitting diodes (LEDs), light lamps and other light sources that produce light at a wavelength or a spectral band to excite a fluorescent material that converts the light of a higher energy into light of lower energy in the visible range. The excitation optical beam that excites a fluorescent material on the screen can be at a frequency or in a spectral range that is higher in frequency than the frequency of the emitted visible light by the fluorescent material. Accordingly, the excitation optical beam may be in the violet spectral range and the ultra violet (UV) spectral range, e.g., wavelengths under 420 nm. In the examples described below, UV light or a UV laser beam is used as an example of the excitation light for a phosphor material or other fluorescent material and may be light at other wavelength.

FIG. 3A illustrates an example of a fluorescent screen 301 having color phosphor stripes. Alternatively, color phosphor dots may also be used to define the image pixels on the screen. The screen 301 has parallel color phosphor stripes in the vertical direction where red phosphor absorbs the laser light to emit light in red, green phosphor absorbs the laser light to emit light in green and blue phosphor absorbs the laser light to emit light in blue. Adjacent three color phosphor stripes are in three different colors. One particular spatial color sequence of the stripes is shown in FIG. 3A as red, green and blue. Other color sequences may also be used. The laser beam 116 is at the wavelength within the optical absorption bandwidth of the color phosphors and is usually at a wavelength shorter than the visible blue and the green and red colors for the color images. As an example, the color phosphors may be phosphors that absorb UV light in the spectral range from about 380 nm to about 420 nm to produce desired red, green and blue light.

FIG. 3B shows an exemplary design of the screen 301 in FIG. 3A. The screen 301 in this particular example includes a rear substrate 311 which is transparent to the scanning laser beam 116 to receive the scanning laser beam 116. A second front substrate 312 is fixed relative to the rear substrate 311 and faces the viewer so that the fluorescent light transmits through the substrate 312 towards the viewer. A color phosphor stripe layer 310 is placed between the substrates 311 and 312 and includes phosphor stripes. The color phosphor stripes for emitting red, green and blue colors are represented by “R”, “G” and “B,” respectively. The front substrate 312 is transparent to the red, green and blue colors emitted by the phosphor stripes. The substrates 311 and 312 may be made of various materials, including glass or plastic panels. Each color pixel includes portions of three adjacent color phosphor stripes in the horizontal direction and its vertical dimension is defined by the beam spread of the laser beam 116 in the vertical direction. As such, each color pixel includes three subpixels of three different colors (e.g., the red, green and blue). In the specific moment during the scan in FIG. 2A, the scanning laser beam 116 is directed at the green phosphor stripe within a pixel to produce green light for that pixel.

FIG. 3C further shows the operation of the screen 301 in a view along the direction perpendicular to the surface of the screen 301. Since each color stripe is longitudinal in shape, the cross section of the beam 116 may be shaped to be elongated along the direction of the stripe to maximize the fill factor of the beam within each color stripe for a pixel. This may be achieved by using a beam shaping optical element. A laser source that is used to produce a scanning laser beam that excites a phosphor material on the screen may be a single mode laser or a multimode laser. The laser may also be a single mode along the direction perpendicular to the elongated direction phosphor stripes to have a small beam spread that is confined by the width of each phosphor stripe. Along the elongated direction of the phosphor stripes, this laser beam may have multiple modes to spread over a larger area than the beam spread in the direction across the phosphor stripe. This use of a laser beam with a single mode in one direction to have a small beam footprint on the screen and multiple modes in the perpendicular direction to have a larger footprint on the screen allows the beam to be shaped to fit the elongated color subpixel on the screen and to provide sufficient laser power in the beam via the multimodes to ensure sufficient brightness of the screen.

Alternatively, FIG. 4 illustrates an example of a fluorescent screen design that has a contiguous and uniform layer 420 of mixed phosphors. This mixed phosphor layer 420 is designed and constructed to emit white light under optical excitation of the excitation light 116. The mixed phosphors in the mixed phosphor layer 420 can be designed in various ways and a number of compositions for the mixed phosphors that emit white light are known and documented. Notably, a layer 410 of color filters, such as stripes of red-transmitting, green-transmitting and blue-transmitting filters, is placed on the viewer side of the mixed phosphor layer 420 to filter the white light and to produce colored output light. The layers 410 and 420 can be sandwiched between substrates 401 and 402. The color filters may be implemented in various configurations, including in designs similar to the color filters used in color LCD panels. In each color filter region e.g., a red-transmitting filter, the filter transmits the red light and absorbs light of other colors including green light and blue light. Each filter in the layer 410 may be a multi-layer structure that effectuates a band-pass interference filter with a desired transmission band. Various designs and techniques may be used for designing and constructing such filters. U.S. Pat. No. 5,587,818 entitled “Three color LCD with a black matrix and red and/or blue filters on one substrate and with green filters and red and/or blue filters on the opposite substrate,” and U.S. Pat. No. 5,684,552 entitled “Color liquid crystal display having a color filter composed of multilayer thin films,” for example, describe red, green and blue filters that may be used in the screen design in FIG. 4. Hence, a fluorescent stripe in the fluorescent screen in various examples described in this application is a fluorescent stripe that emits a designated color under optical excitation and can be either a fluorescent stripe formed of a particular fluorescent material that emits the designated color in FIG. 3A or a combination of a stripe color filter and a white fluorescent layer in FIG. 4.

FIG. 5 shows an example implementation of a post-objective scanning beam display system based on the system design in FIG. 1. A laser array 510 with multiple lasers is used to generate multiple laser beams 512 to simultaneously scan a screen 501 for enhanced display brightness. The screen 501 can be a passive screen or an active screen. The laser array 510 can be implemented in various configurations, such as discrete laser diodes on separate chips arranged in an array and a monolithic laser array chip having integrated laser diodes arranged in an array. A signal modulation controller 520 is provided to control and modulate the lasers in the laser array 510 so that the laser beams 512 are modulated to carry the image to be displayed on the screen 501. The signal modulation controller 520 can include a digital image processor which generates the digital image signals for the three different color channels and laser driver circuits that produce laser control signals carrying the digital image signals. The laser control signals are then applied to modulate the lasers in the laser array 510, e.g., electric currents that drive the laser diodes. The laser beams 512 can be of different wavelengths (e.g., red, green and blue colors for a display with a passive screen 501) or of the same wavelength (e.g., either to increase the intensity of light to produce a monochromatic pattern on a passive surface 501 or an excitation light beam that excites phosphors on an active phosphor screen 501 in FIG. 3A).

The beam scanning is based on a two-scanner system in FIG. 1. Each of the different reflective facets of the polygon scanner 140 simultaneously scans N horizontal lines where N is the number of lasers. A relay optics module 530 reduces the spacing of laser beams 512 to form a compact set of laser beams 532 that spread within the facet dimension of the polygon scanner 140 for the horizontal scanning. Downstream from the polygon scanner 140, there is a 1-D horizontal scan lens 120 followed by a vertical scanner 150 (e.g., a galvo mirror) that receives each horizontally scanned beam 532 from the polygon scanner 140 through the 1-D scan lens 120 and provides the vertical scan on each horizontally scanned beam 532 at the end of each horizontal scan prior to the next horizontal scan by the next facet of the polygon scanner 140.

Under this optical design of the horizontal and vertical scanning, the 1-D scan lens 120 is placed downstream from the polygon scanner 140 and upstream from the vertical scanner 150 to focus each horizontal scanned beam on the screen 501 and minimizes the horizontal bow distortion to displayed images on the screen 501 within an acceptable range, thus producing a visually “straight” horizontal scan line on the screen 501. Such a 1-D scan lens 120 capable of producing a straight horizontal scan line is relatively simpler and less expensive than a 2-D scan lens of similar performance. Downstream from the scan lens 120, the vertical scanner 150 is a flat reflector and simply reflects the beam to the screen 501 and scans vertically to place each horizontally scanned beam at different vertical positions on the screen 501 for scanning different horizontal lines. The dimension of the reflector on the vertical scanner 150 along the horizontal direction is sufficiently large to cover the spatial extent of each scanning beam coming from the polygon scanner 140 and the scan lens 120. The system in FIG. 5 is a post-objective design because the 1-D scan lens 120 is upstream from the vertical scanner 150. In this particular example, there is no lens or other focusing element downstream from the vertical scanner 150.

This optical design eliminates the need for a complex and expensive 2-D scan lens 120 in pre-objective scanning beam displays where the scanning lens is located downstream from the two scanners 140 and 150 and focuses the a scanning excitation beam onto a screen. In such a pre-objective design, a scanning beam directed into the scan lens is scanned along two orthogonal directions. Therefore, the scan lens is designed to focus the scanning beam onto the screen along two orthogonal directions. In order to achieve the proper focusing in both orthogonal directions, the scan lens can be complex and, often, are made of multiples lens elements. In one implementation, for example, the scan lens can be a two-dimensional f-theta lens that is designed to have a linear relation between the location of the focal spot on the screen and the input scan angle (theta) when the input beam is scanned around each of two orthogonal axes perpendicular to the optic axis of the scan lens. In such a f-theta lens, the location of the focal spot on the screen is a proportional to the input scan angle (theta).

The two-dimensional scan lens such as a f-theta lens in the pre-objective configuration can exhibit optical distortions along the two orthogonal scanning directions which cause beam positions on the screen to trace a curved line. Hence, an intended straight horizontal scanning line on the screen becomes a curved line. The distortions caused by the 2-dimensional scan lens can be visible on the screen and thus degrade the displayed image quality. One way to mitigate the bow distortion problem is to design the scan lens with a complex lens configuration with multiple lens elements to reduce the bow distortions. The complex multiple lens elements can cause the final lens assembly to depart from desired f-theta conditions and thus can compromise the optical scanning performance. The number of lens elements in the assembly usually increases as the tolerance for the distortions decreases. However, such a scan lens with complex multiple lens elements can be expensive to fabricate.

To avoid the above distortion issues associated with a two-dimensional scan lens in a pre-objective scanning beam system, the following sections describe examples of a post-objective scanning beam display system, which can be implemented to replace the two-dimensional scan lens with a simpler, less expensive 1-dimensional scan lens 120 shown in FIG. 5.

FIGS. 6A, 6B and 6C illustrate a specific example of the post-objective design of the beam scanning module in FIG. 5. The 1-D scan lens 120 can be a compound lens with multiple lens elements to achieve desired 1-D focusing of a horizontally scanned beam with no horizontal bow distortion. The 1-D scan lens 120 can have an elongated shape along the horizontal scanning direction of the beam and is placed within the same plane 600 that is perpendicular to the vertical polygon rotation axis. The vertical scanner 150 pivots around a horizontal axis which lies in the plane 600. The pivoting of the vertical scanner 150 directs beams reflected from different polygon facets to different vertical directions to trace out different horizontal scan lines on the screen 501. FIG. 6B shows the cross section view of the beam scanning module 4920 along the lines BB in FIG. 6A which is a view along the lines AA in FIG. 6B. FIG. 6C further shows a perspective view of the beam scanning module 4920 to show different horizontal positions of a horizontally scanned beam by along a straight horizontal line from a single polygon facet. The 1-D scan lens 120 in the above example is a 4-element compound lens as shown in FIGS. 6A and 6B.

Notably, the distance from the scan lens to a location on the screen 501 for a particular beam varies with the vertical scanning position of the vertical scanner 150. Therefore, when the 1-D scan lens 120 is designed to have a fixed focal distance along the straight horizontal line across the center of the elongated 1-D scan lens, the focal properties of each beam must change with the vertical scanning position of the vertical scanner 150.

FIG. 7 illustrates examples of the changes in the beam size and shape on the screen 501 for the post-objective design in FIGS. 6A-6C along different horizontal positions on the screen 501. In this spot diagram for a horizontal set of beams at different horizontal positions and the same vertical position on the screen, the end spots located on two sides of the screen are more elongated because of the large angle of incidence of the laser which is about 42 degrees in the setup for the measurements shown.

FIG. 8 further shows beam widths at different representative positions on the screen 501: middle center, middle edge, top center and top corner or edge. Hence, in order to maintain the beam size to be at a constant size, a dynamic focusing mechanism is implemented to adjust convergence of the beam going into the 1-D scan lens 120 based on the vertical scanning position of the vertical scanner 150.

Referring back to FIG. 6B, an example of the dynamic focusing mechanism is illustrated. In the optical path of the one or more laser beams from the lasers to the polygon scanner 140, a stationary lens 620 and a dynamic refocus lens 630 are used as the dynamic focusing mechanism. Each beam is focused by the dynamic focus lens 630 at a location upstream from the stationary lens 620. When the focal point of the lens 630 coincides with the focal point of the lens 620, the output light from the lens 620 is collimated. Depending on the direction and amount of the deviation between the focal points of the lenses 620 and 630, the output light from the collimator lens 620 toward the polygon scanner 140 can be either divergent or convergent. Hence, as the relative positions of the two lenses 620 and 630 along their optic axis are adjusted, the focus of the scanned light on the screen 501 can be adjusted. Alternatively, the lens 620 may be adjustable while the lens 630 is fixed in position or both lenses 620 and 630 are adjustable to change their positions for changing the focus of the beam sent to the screen.

A refocusing lens actuator 640 can be used to adjust the relative position between the lenses 620 and 630 in response to a control signal 650. In this particular example, the refocusing lens actuator 5410 is used to adjust the convergence of the beam directed into the 1-D scan lens 120 along the optical path from the polygon scanner 140 in synchronization with the vertical scanning of the vertical scanner 150. The actuator 640 is controlled to adjust the position of the lens 630 relative to an upstream focal point of the lens 620 to change the beam convergence at the entry of the 1-D scan lens 120. A control module can be provided to synchronize the actuator 640 and the vertical scanner 150 by sending a refocusing control signal 650 to control the operation the of actuator 640. For example, if the collimation lens 620 with a focal length of 8 mm is used, then the adjustment can be a distance of less than 10 microns at the lens 630 to provide sufficient refocusing for a screen of over 60″ in the diagonal dimension.

In addition to the beam size and the beam focus, the change of the distance from the scan lens 120 to a location on the screen 501 for a particular beam due to different vertical scanning positions of the vertical scanner 150 also creates a vertical bow distortion on the screen 501. Assuming the vertical scanner 150 directs a beam to the center of the screen 501 when the vertical angle of the vertical scanner 150 is at zero where the distance between the screen 501 and the vertical scanner 150 is the shortest. As the vertical scanner 150 changes its vertical orientation in either vertical scanning direction, the horizontal dimension of each horizontal line increases with the vertical scanning angle.

FIG. 9 illustrates this bow distortion. Different from classical barrel distortions in lenses, this distortion is geometrical in nature and is caused by the change in the vertical scanning angle of the vertical scanner 150. This distortion essentially changes the beam spot spacing of beam spots from a regular chain of optical pulses in each scanning beam along the horizontal direction across the screen 501. Therefore, the above-described digital technique of controlling timing of laser pulses in the scanning beam during each horizontal scan can be applied to correct this distortion.

During a horizontal scan, the time delay in timing of a pulse can cause the corresponding position of the laser pulse on the screen to spatially shift downstream along the horizontal scan direction. Conversely, an advance in timing of a pulse can cause the corresponding position of the laser pulse on the screen to spatially shift upstream along the horizontal scan direction. A position of a laser pulse on the screen in the horizontal direction can be controlled electronically or digitally by controlling timing of optical pulses in the scanning beam. Therefore, the timing of the pulses in the scanning beam can be controlled to direct each optical pulse to a location that reduces or offsets the horizontal displacement of the beam caused by the vertical scanning of the vertical scanner 150. This can be achieved by obtaining the amounts of the horizontal position shift at each beam location caused by the vertical scanning in each of all horizontal scan lines at different vertical scanning positions on the screen. The timing of the laser pulses is then controlled during each horizontal scanning to offset the obtained amounts of the horizontal position shift at different beam locations and at different vertical scanner positions. Notably, this control of the timing of laser pulses is separate from, and can be simultaneously implemented with, the control of timing of laser pulses in aligning laser pulses to proper phosphor color stripes during a horizontal scan based on the servo feedback described in PCT patent application No. PCT/US2007/004004 entitled “Servo-Assisted Scanning Beam Display Systems Using Fluorescent Screens” and filed Feb. 15, 2007 and published as PCT publication No. WO/2007/095329 on Aug. 23, 2007, and PCT patent application No. PCT/US2006/11757 entitled “Display Systems and Devices Having Screens With Optical Fluorescent Materials” and filed Mar. 31, 2006 and published as PCT publication No. 2006/107720 on Oct. 12, 2006. Various servo mark designs on screens and servo feedback techniques described in the above two PCT applications can be applied to the post-objective scanning beam systems described in this application. The entire disclosures of the above two PCT applications are incorporated by reference as part of the specification of this application.

The post-objective designs described above can be used to reduce dimension of a rear-projection display system using a folded optical path design. FIG. 10 shows one example of a rear-projection display based on a post-objective scanning beam design of this application. The screen 501 is placed above the plane 500 in which the polygon scanner 140, the 1-D scan lens 120 and the center of the vertical scanner 150 are located. The screen lower edge of the display area (e.g., the area with fluorescent stripes in FIG. 3A) of the screen 501 is above the plane 600 by a chin height H. It can be desirable to reduce the chin height H in such systems to reduce the size of the display. It can also be desirable to reduce the depth D of the display to about 13.5″ or less. A combination of the folded optical path and the post-objective configuration allows both H and D to be minimized.

In this example, the screen 501 can be approximately perpendicular to the plane 600. A folding reflector 1010 is provided at the excitation side of the screen 501 to reflect light from the vertical scanner 150 to the screen 501. The reflector 1010 can be oriented at an angle with respect to the screen 501 and has one end 1011 to be close to or in contact with the upper side of the active display area of the screen 501 to reflect light to the upper side the active display area. The dimension and angle of the reflector 1010 are set to allow the other end 1012 of the reflector 1010 to reflect light from the vertical scanner 150 near the lower edge of the active area of the screen 501. The vertical scanner 150 can be placed as close to the inner side of the screen 501 as possible to minimize the depth D of the display.

In the above post-objective scanning designs, the 1-D scan lens is placed downstream from the polygon horizontal scanner 140 which provides a high-speed horizontal scan (e.g., 1080 successive scans per frame for a 1080-p display) and upstream from the vertical scanner 150 which provides a lower speed vertical scan (e.g., one scan per frame). Under this configuration, the refocusing control by the actuator 640 is synchronized with the lower-speed vertical scan of the vertical scanner 150 and thus allows for a slower actuator to be used as the actuator 640 for the refocusing. Accordingly, various issues associated with using a high-speed actuator for the refocusing mechanism, such as cost, feasibility, and refocusing speed and accuracy are avoided.

Referring to FIG. 6B, the vertical scanner 150 has a dimension W sufficiently large to receive the horizontally scanned beam from the 1-D scan lens 120. This dimension W is much larger (e.g., 134 mm) than the vertical scanner used in pre-objective scanning system and can present technical issues in designing the vertical scanner 150. For example, the distortion in the shape of the vertical scanner 150 can distort a horizontal scan line and thus compromise the image quality.

Electromagnetic galvo mirrors can be used to implement the vertical scanner 150.

FIGS. 11, 12 and 13 illustrate three examples where the coils are designed to provide a torque along the full length of the mirror. FIG. 11 shows a permanent magnet type rotor with a slotted stator. In FIG. 12, a permanent magnet type rotor with smooth stator windings is shown. FIG. 13 shows a stepper motor type galvo motor-mirror where the mirror can be hollowed out to reduce the inertia.

Notably, the various servo control techniques described in connection with the pre-objective display systems can be applied to the post-objective scanning beam displays.

The post-objective scanning beam systems based on the designs described in this application can be applied to display systems and other optical systems that use scanning beams to produce optical patterns. For example, laser printing systems can also use the above described post-objective scanning systems where the screen is replaced by a printing medium (e.g., paper, fabric, or a master printing plate. A post-object scanning design based on this application can yield high diagonal-to-depth ratios, e.g., 4:1 or greater, and achieve a thinner display systems to reduce the depth of the projection optical module.

The above examples of post-object scanning beam systems use a polygon scanner 140 for horizontal scanning as the first beam scanner placed upstream from the scan lens 120 and a vertical scanner 150 such as a galvo mirror as the second beam scanner for vertical scanning downstream from the scan lens 120. In other implementations, the first beam scanner located upstream from the scan lens 120 is a vertical scanner 150 for vertical scanning, such as a galvo mirror, and the second scanner downstream from the scan lens 120 is a polygon scanner 140 for horizontal scanning. This configuration can be designed to use a small glavo reflector and thus avoid a large downstream galvo reflector with a dimension along the horizontal scanning direction of the upstream polygon needed for the post-objective system in FIG. 1. A large glavo reflector can require more power to operate than a small galvo reflector and its dynamic range may be limited due to the larger mass in comparison with a small galvo reflector. In this system, the distortion pattern is rotated relative to the other one and is preferable for RGB vertical lines because strong distortion in the vertical direction makes the spot rotate which means effectively a wider spot.

FIG. 14 illustrates an example of this post-objective configuration. The laser beam 112 from the laser 110 is directed to the vertical scanner 150 which scans the beam in the vertical direction as the 1-D scanning beam 1410 and directs the beam 1410 through the scan lens 120 to the second scanner 140 which is a polygon scanner. The output beam 1420 from the polygon scanner 140 is a 2-D scanning beam and is directed to a target surface 101. In one implementation, the scan lens 120 can be designed to image the reflective surface of the vertical scanner 150 onto the reflecting facet of the polygon 140 so that a relatively small polygon facet of a compact polygon can be used to reduce power consumption and the dynamic range of the polygon.

FIG. 15 show an example of a laser scanning display system based on multiple lasers in a laser array 510 based on the post-objective design in FIG. 14. This scanning beam display system includes lasers forming a laser array 510 to produce multiple laser beams, respectively, a beam scanning module with two scanners 150 and 140 placed in an optical path of the laser beams to scan the laser beams in two orthogonal directions onto the screen 101; and an afocal optical relay module 1510 placed between the lasers and the scanning module to include lenses to reduce a spacing between two adjacent laser beams and to overlap the laser beams at the scanning module. Mirrors 1541 and 1542 are placed in the optical path between the polygon scanner 140 and screen 101 to fold the optical path with a small optical depth.

In one implementation, the afocal optical relay module can include a first lens having a first focal length to receive and focus the laser beams from the lasers; a second lens having a second focal length shorter than the first focal length and spaced from the first lens by the first focal length to focus the laser beams from the first lens; and a third lens having a third focal length longer than the second focal length and spaced from the second lens by the third focal length to focus and direct the laser beams from the second lens to the scanning module. Examples for the afocal optical module 1510 and the optical relay module 530 are described in PCT application No. CT/US2006/041584 entitled “Optical Designs for Scanning Beam Display Systems Using Fluorescent Screens” and filed on Oct. 25, 2006 (PCT publication no. WO 2007/050662) and U.S. patent application Ser. No. 11/510,495 entitled “Optical Designs for Scanning Beam Display Systems Using Fluorescent Screens” and filed on Aug. 24, 2006 (U.S. publication no. US 2007-0206258 A1), which are incorporated by reference as part of the specification of this application.

In FIG. 15, the laser beams are controlled to overlap in a single plane (i.e., the pupil plane). A single-axis scanning scanner upstream from the scan lens 120, e.g., a galvo mirror, is located in the pupil plane and is used to scan all beams along one axis, which is the vertical direction in this example. The scan lens 120 can be a multi-function scan lens which is designed to have a sufficiently large field-of-view to accept the full angular range of the scanned beams from the upstream vertical scanner 150 (e.g., the galvo mirror). The scan lens 120 is a converging lens which brings the beams to focus at the screen 101. The scan lens 120 is also used to image the galvo mirror 150 onto the polygon reflecting facet on the downstream polygon scanner 140. This imaging function allows the polygon 140 to be relatively small. Without imaging, the polygon would be relatively large because the scanned beams naturally spread with increasing distance from the galvo mirror 140. The scan lens 120 in FIG. 15 is illustrated as a single-element lens. Such a lens 120 can be designed to include multiple lens elements in order to perform its functions, e.g., focusing and re-imaging over the scanning range of the galvo mirror 140.

Downstream from the scan lens 120, the polygon scanner 140 scans the converging beams from the scan lens 120 onto the screen 101. The foci of the converging beams can, in general, lie on a curved surface. A focus servo is used to refocus the beams dynamically on to a planar surface of the screen 101. In this example, the focus servo includes at least two lens elements 1520 and 1530 that are separated by an air gap as shown. One of the two lenses (e.g., lens 1520) has a positive focal length and the other (e.g., lens 1530) has a negative focal length. An actuator is provided to control the relative spacing between the two lenses 1520 and 1530. The beams entering and exiting the focus servo are nominally collimated when the lenses comprising the focus servo are separated by a prescribed distance (i.e., the neutral or nominal position). In the example shown in FIG. 15, one lens of the focus servo is stationary and the other is moved axially to allow dynamic refocusing of the beams. The movable lens (e.g., lens 1530) is moved about its nominal position by a distance sufficient to bring the beams to focus on the screen 101.

In the above post-objective systems, the output 20-D scanning beam can have optical distortions. FIG. 16 shows an example of a distorted image on the screen 101 produced by a system based on the design in FIG. 15. In this example, there are “bow” distortions in the horizontal direction and no significant geometric distortion in the vertical direction. A distortion correcting optical module 1550 with multiple lens elements can be provided in the optical path between the polygon scanner 150 and the screen 101 to reduce the optical distortions (FIG. 15).

While this specification contains many specifics, these should not be construed as limitations on the scope of an invention or of what may be claimed, but rather as descriptions of features specific to particular embodiments of the invention. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or a variation of a sub-combination.

Only a few implementations are disclosed. However, it is understood that variations and enhancements may be made.

Claims

1. A scanning beam display system, comprising: a light source that produces a beam of light;a first beam scanner located in a plane to scan the beam of light along a first direction;a second beam scanner located in the plane to scan the beam of light received from the first beam scanner along a second direction different from the first direction;a screen having a display surface that is substantially perpendicular to and is located entirely on one side of the plane in which the first and second beam scanners are located, the screen being positioned to have one edge closer to the second beam scanner which scans the beam of light in beam directions that are not directed to the screen than to the first beam scanner; andan optical reflector located on the side of the plane where the screen is located and has one end positioned away from the screen, the optical reflector oriented to reflect the beam of light from the second beam scanner onto the screen along a folded optical path to scan the beam of light along the first and the second directions on the screen.

2. The system as in claim 1, comprising: a scan lens placed in an optical path of the beam of light between the first and the second beam scanners to direct the beam of light from the first beam scanner along a line on the second beam scanner and to focus the beam of light via the folded optical path onto the screen.

3. The system as in claim 1, wherein: the first beam scanner is a polygon scanner comprising a plurality of different reflective facets, andthe second beam scanner is a 1-dimensional beam scanner.

4. The system as in claim 3, comprising: a beam focusing servo control module to dynamically control focus of the beam onto the screen to maintain a constant beam spot size of the beam of light on the screen at different locations.

5. The system as in claim 3, comprising: an optical distortion correcting module placed downstream from the second beam scanner to transmit the beam from the second beam scanner and configured to correct optical distortions in the beam.

6. The system as in claim 1, comprising: a beam focusing element placed in an optical path of the beam of light to adjust a focus of the beam of light on the screen; andan actuator coupled to the beam focusing element to adjust a position of the beam focusing element, in response to a control signal, to adjust the focus in synchronization with scanning of the second beam scanner to maintain a constant beam spot size of the beam of light on the screen at different locations.

7. The system as in claim 6, wherein: the beam focusing element comprises a first lens and a second lens that are spaced from each other in an optical path of the beam of light, andthe actuator is engaged to at least one of the first and second lenses to adjust a spacing between the first and second lenses.

8. The system as in claim 1, wherein: the display surface of the screen is made of a material that absorbs light of the beam of light to emit light which presents images carried in the beam of light to a viewer.

9. The system as in claim 8, wherein: the surface comprises phosphor materials.

10. The system as in claim 8, wherein: the surface comprises parallel stripes of phosphor materials.

11. The system as in claim 1, wherein: the light source comprises lasers that produce laser beams to constitute the beam of light.