JP2007058240A - Prism, method of manufacturing prism, optical unit and projection type display device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a prism capable of preventing uneven luminance caused by the structure of a prism center part and also preventing an adhesion part from being peeled even when the prism is molded with a plastic material. <P>SOLUTION: Concave lenses are formed on incident surfaces 271a, 272a, 273a of the prism 27. Further, a convex lens is formed on an exit surface 274a. As for the constitution of the joint part of prism pieces, a dichroic multilayered film is formed on one surface side of the adhesion layer and a single layer film is formed on the other surface side. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a prism for a projection display device that separates color light from incident light or emits light by combining a plurality of color lights, or separates incident light into different kinds of polarized light.

  The prior art will be described below with reference to FIGS.

  FIG. 14 shows a configuration example of a conventional projection display apparatus. In FIG. 14, the white light beam 3 from the light source 1 is converted into a uniform white light beam by the reflector 2 of the parabolic mirror, the first lens array 4, the cold mirror 5, and the second lens array 6. The red light beam 8 and the blue / green light beam 13 are separated by the green reflecting dichroic mirror 7. The red light beam 8 is reflected by the increasing reflection mirror 9, passes through the condenser lens 10, and enters the red light transmissive liquid crystal panel 12. The blue / green light beam 13 is separated into a green light beam 15 and a blue light beam 19 by the green reflecting dichroic mirror 14. The green light beam 15 passes through the condenser lens 16 and is incident on the transmissive liquid crystal panel 18 for green light. The blue light beam 19 is incident on the blue light transmissive liquid crystal panel 26 through the relay lens 20, the increasing reflection mirror 21, the relay lens 22, the increasing reflection mirror 23, and the condenser lens 24. A red light beam including image information emitted from the transmissive liquid crystal panel 12 for red light, a green light beam including image information emitted from the transmissive liquid crystal panel 18 for green light, and a transmissive liquid crystal panel 26 for blue light. Each of the blue luminous fluxes including the image information is incident on the prism 57. In the prism 57, the light beams of the respective colors are combined, and the combined light is emitted from the light emitting surface toward the projection lens unit 58. The projection lens unit 58 enlarges the combined light as image light and projects it on a screen to display an image. The light source 1 is driven by a light source power supply circuit 80. The liquid crystal panels 12, 18, and 26 are driven by the drive circuit 70 based on the image signal input from the input terminal 60, and transmit the corresponding color light beams (color light) in a modulated state.

  FIG. 15 shows a top view of the prism 57. In FIG. 15, a red light beam including image information emitted from the transmissive liquid crystal panel 12 for red light enters the prism 57 from the surface 571a, and is reflected at an angle of approximately 90 degrees on the bonding surface 571b and the bonding surface 573b. The light is emitted from the surface 574a. The blue light beam including the image information emitted from the transmissive liquid crystal panel 26 for blue light enters the prism 57 from the surface 573a, is reflected by 90 degrees on the bonding surface 572b and the bonding surface 574b, and is emitted from the surface 574a. . The green light beam including the image information emitted from the transmissive liquid crystal panel 18 for green light is incident on the prism 57 from the surface 572a, passes through the bonding surfaces 571b, 572b, 573b, and 574b, and is emitted from the surface 574a. Reference numerals 571, 572, 573, and 574 are triangular prisms each having a cross section of a right isosceles triangle made of glass having the same refractive index. The emitted light 59 which is color-synthesized and includes image information is projected on a screen (not shown) by the projection lens unit 58 and displayed as an image.

  FIG. 12 is a perspective view of the prism, and FIG. 13 is an enlarged sectional view of the prism. In the prism 57, four triangular prisms 571, 572, 573, and 574 made of glass having an isosceles right triangular section and the same refractive index are bonded to each other with an adhesive 57g. On the bonding surfaces 571b and 573b, a red reflection film 57r having a selective reflection characteristic of red light is formed. A blue reflective film 57b having a blue selective reflection characteristic is formed on the bonding surfaces 572b and 574b. As is clear from FIG. 12, the triangular prisms 573 and 574 are longer in the vertical direction than the triangular prisms 571 and 572. The prism 57 is configured by bonding so that the bonding surfaces of the triangular prisms 572 and 573 and the bonding surfaces of the triangular prisms 571 and 574 are linear. FIG. 17 is a diagram showing the line width δ of one of the four triangular prisms (here, triangular prism 571), and FIG. 16 shows the four triangular prisms bonded together without any deviation. It is a figure which shows line | wire width (delta) of the center part 57d of a prism at the time. When the deviation occurs, the line width δ of the center line of the prism is increased as shown in FIG. The prism 57 is held by a prism holder (not shown) as a holding member, and forms a color synthesizing unit of the projection display device.

  For example, Japanese Patent Publication No. 7-109443 and Japanese Patent Application Laid-Open No. 8-184797 disclose conventional projection display devices having color composition means.

Japanese Examined Patent Publication No. 7-109443 JP-A-8-184797

The above prior art has the following problems. That is,
(1) Since light is blocked by the central portion 57d of the prism, vertical stripe-like luminance unevenness occurs on the screen. FIG. 16 shows the relationship between the width δ of the central portion 57d of the prism and the illuminance ratio. For example, if the width δ of the ridge line of the triangular prism is 10 μm or more, the width δ of the central portion of the prism is also 10 μm or more, and the illuminance ratio between the central portion projected on the screen and the adjacent region at that time is The difference becomes 3% or more, and the image quality deteriorates. Further, as shown in FIG. 13, there is a gap due to an adhesive between the blue reflecting film 57b on the triangular prism 574b surface and the blue reflecting film 57b on the triangular prism 572b surface. Become bigger. There is also a gap due to an adhesive between the red reflecting film 57r on the triangular prism 571b surface and the red reflecting film 57r on the triangular prism 573b surface. In this case, the width at which light is not reflected is larger than the width δ. As described above, the reflected light of the red light beam and the blue light beam easily generates vertical stripe-like luminance unevenness on the screen.

  (2) When the prism is made of a plastic material or the like, the prism of the lamp or the like expands due to heat and adheres to the surface of the plastic material due to the difference in coefficient of thermal expansion between the plastic material, the reflective film, and the adhesive. The interface of the agent peels off. For example, the same applies to a temperature cycle test performed between minus 30 ° C. and plus 70 ° C. This is because the peel strength between the plastic material and the adhesive is weaker than the peel strength at the interface between the plastic material and the thin film, and the peel strength between the plastic material and the adhesive is weaker than the peel strength at the interface between the thin film and the adhesive. It is thought to be the cause.

  In view of the above-described prior art, the problems of the present invention are: (1) suppressing vertical stripe-like luminance unevenness caused by the configuration of the central portion of the prism, and (2) configuring the prism with a plastic material or the like. In this case, the adhesive does not peel off.

  The objective of this invention is providing the technique which can solve this subject.

  In order to solve the above-mentioned problems, in the present invention, (a) a concave lens is formed on the light incident surface of the prism in order to suppress vertical stripe-shaped luminance unevenness. (B) A concave lens is formed on the light incident surface of the prism, and a convex lens is formed on the light emitting surface. (C) In (a) or (b), a concave lens is formed on each color light incident surface of red light, green light, and blue light. In addition, in order to prevent peeling of the adhesive portion between the prism pieces, (d) as a configuration of the bonded portion between the prism pieces, a dichroic multilayer film is formed on one surface side of the adhesive layer, and the other surface A single layer film is formed on the side.

Specifically, (i) to (d) above are:
(1) A concave lens is formed on a light incident surface as a prism that separates colored light from incident light or combines and emits a plurality of colored lights.

  (2) As a prism that separates colored light from incident light or combines and emits a plurality of colored lights, a concave lens is formed on the light incident surface, and a convex lens is formed on the light emitting surface.

  (3) In the above (1) or (2), the light incident surface is formed such that concave lenses are formed on the color light incident surfaces of red light, green light, and blue light.

  (4) As a prism that separates colored light from incident light or synthesizes and emits a plurality of colored lights, a plurality of triangular prisms are bonded together, and an adhesive layer and a prism surface in all or a part of the bonded portions A thin film is provided between the two.

  (5) In the above (4), one of the thin films is a single layer film, and the other is a multi-layer film reflecting a specific color light.

  (6) In the above (4), four triangular prisms are used, four of the eight bonded portions are formed with a multilayer film reflecting specific color light, and the other four bonded. A single layer film is formed in the part.

  (7) In the above (4), four triangular prisms are used, and a multilayer film reflecting specific color light is formed in four of the eight bonded portions, and the other three bonded. A single layer film is formed in the part.

(8) In the above (5), (6) or (7), the single layer film is composed of SiOx (x is a number including a decimal point of 1 to 2) or a mixed material of SiO ₂ and aluminum oxide. So that

(9) In the above (8), the mixed material of SiO ₂ and aluminum oxide is such that the refractive index of light is in the range of about 1.48 to 1.54.

  (10) In any one of the above (5) to (9), the multilayer film includes a layer of SiOx (x is a number including a decimal point from 1 to 2).

  (11) In any one of the above (4) to (10), the triangular prismatic prism is made of a plastic material.

  (12) As an optical unit for the projection display device, a panel that modulates the separated color light based on image information, and a concave lens formed on the light incident surface, and the modulated light from the panel that is incident through the concave lens portion And a projection means for enlarging and projecting the color synthesized light on the screen.

  (13) As an optical unit for a projection display device, a panel that modulates separated color light based on image information, a concave lens on a light incident surface, and a convex lens on a light output surface are formed and incident through the concave lens portion. And a prism that synthesizes the modulated light from the panel and emits the light from the convex lens unit, and a projection unit that enlarges and projects the emitted color synthesized light on a screen.

  (14) As an optical unit for a projection display device, a panel that modulates separated color light based on image information and a plurality of triangular prisms are bonded together, and an adhesive is used in all or part of the bonded portion. A dichroic thin film or a single-layer thin film provided between the layer and the prism surface, and a prism for synthesizing and emitting the modulated light from the panel; and a projection means for enlarging and projecting the color synthesized light on the screen; It is set as the structure provided with.

  (15) The projection display device includes the optical unit of any one of (12) to (14), a drive circuit that drives the panel, and a power supply circuit that drives the light source.

  (16) As a method for manufacturing a prism, a step of injection-molding a triangular prism with a plastic, a step of holding the molded product in a temperature range of a predetermined range for a predetermined time, a step of cooling thereafter, and a first reflective film A prism is manufactured through a step of forming a single-layer film, bonding a triangular prism, and a step of forming a second reflective film and bonding a triangular prism.

  (17) As a prism that separates incident light into different kinds of polarized light, a plurality of triangular prisms are bonded together, and a thin film is provided between the adhesive layer and both prism surfaces at the bonded portion. Is configured such that one is a single layer film and the other is a polarized light separation film having selectivity for polarized light.

  (18) As a projection display device, the prism of (17) above, a panel that modulates the separated color light based on image information, a drive circuit that drives the panel, and the color combined light are enlarged on the screen. It is set as the structure provided with the projection means to project.

In the above, the concave lens on the light incident surface of the prism enlarges the light beam cross-sectional area of the incident light in the prism, reduces the ratio of the light beam blocked by the ridge line at the center of the prism, and reduces the luminance unevenness on the screen. The convex lens on the light exit surface of the prism reduces the cross-sectional area of the light beam and emits it from the prism as combined light in a focused state. In a state where the projection lens unit is coupled, the converged combined light is incident on the projection lens unit. Further, the single layer film such as SiO _{2 in the} bonded portion functions to improve the adhesion of the adhesive layer on the surface of the triangular prism prism (prism piece), and the triangular prism prism (prism piece) is made of a plastic material or the like. Even when configured, peeling of the adhesive layer is prevented. The multi-layer film of the bonding portion reflects specific color light, thereby separating color light from incident light or synthesizing a plurality of color lights.

  According to the present invention, it is possible to improve image quality by reducing streaks on the screen due to the prism. Moreover, even when a plastic material is used for the triangular prism, a bonding strength capable of preventing peeling can be obtained.

  Embodiments of the present invention will be described below with reference to the drawings. In the drawings, common parts are denoted by the same reference numerals.

  FIG. 1 is a configuration diagram of a projection display device as an embodiment of the present invention. In this embodiment, a prism having a concave lens on the light incident surface and a convex lens on the light emitting surface is used as the prism.

  In FIG. 1, reference numeral 27 denotes a prism, and 28 denotes a projection lens unit that projects outgoing light 29 from the prism 27 onto a screen (not shown). As in the case of FIG. 14, the white light beam 3 from the light source 1 is made into a uniform white light beam by the reflector 2, the first lens array 4, the cold mirror 5, and the second lens array 6, and is blue / green. The red light beam 8 and the blue / green light beam 13 are separated by the reflective dichroic mirror 7. The red light beam 8 is reflected by the increasing reflection mirror 9, passes through the condenser lens 10, and enters the red light transmissive liquid crystal panel 12. The blue / green light beam 13 is separated into a green light beam 15 and a blue light beam 19 by the green reflecting dichroic mirror 14. The green light beam 15 is incident on the transmissive liquid crystal panel 18 for green light. The blue light beam 19 is incident on the blue light transmissive liquid crystal panel 26 through the relay lens 20, the increasing reflection mirror 21, the relay lens 22, the increasing reflection mirror 23, and the condenser lens 24. A red light beam including image information emitted from the transmissive liquid crystal panel 12 for red light, a green light beam including image information emitted from the transmissive liquid crystal panel 18 for green light, and a transmissive liquid crystal panel 26 for blue light. The blue luminous fluxes including the image information are respectively incident on the concave lens portions of the light incident surfaces 271a, 272a, and 273a of the prism 27. In the prism 27, the color light beams are combined and emitted from the convex lens portion of the light emission surface 274a toward the projection lens unit 28. The projection lens unit 28 enlarges the combined light as image light and projects it on a screen to display an image. The light source 1 is driven by a light source power supply circuit 80, and each of the liquid crystal panels 12, 18, and 26 is driven by a drive circuit 70 based on an image signal input from an input terminal 60, and modulates each corresponding color light beam (color light). Transmit in state. In the configuration of this embodiment, the optical components arranged in the optical path from the light source 1 to the projection lens unit 28 form an optical unit.

  FIG. 2 is a top view of the prism 27 as the first embodiment shown in FIG.

  In FIG. 2, a red light beam 8, a blue light beam 19, and a green light beam 15 are incident on a prism 27. The red light beam 8 which is emitted from the red light transmission type liquid crystal panel 12 and includes image information enters the prism 27 from the surface 271a. In the present embodiment, the 271a surface is a concave lens having a radius of about 500 mm. The red light beam 8 that has passed through the surface 271a is reflected by the bonding surfaces 271b and 273b and is emitted from the surface 274a to the outside of the prism. The blue light beam 19 including the image information emitted from the blue light transmission type liquid crystal panel 26 is incident from the surface 273a of the color synthesis cross prism 27. In the present embodiment, the 273a surface is a concave lens having a radius of about 499 mm. The blue light beam 19 that has passed through the surface 273a is reflected by the bonding surfaces 272b and 274b and is emitted from the surface 274a to the outside of the prism. Further, the green light beam 15 including the image information emitted from the green light transmission type liquid crystal panel 18 enters the prism 27 from the surface 272a. In the present embodiment, the 272a surface is a concave lens having a radius of about 497 mm. The green light beam 15 that has passed through the surface 272a passes through the bonding surfaces 271b, 272b, 273b, and 274b, and exits the prism from the surface 274a. In the present embodiment, the surface 274a is a convex lens having a radius of about 500 mm. The red image modulated by the red light transmissive liquid crystal panel 12, the green image modulated by the green light transmissive liquid crystal panel 18, and the blue image modulated by the blue light transmissive liquid crystal panel 26 are respectively at the light incident surface portion. Since it passes through the concave lens, the light beam spreads in the prism. With such a spread light beam, the ratio of the light beam kicked (obstructed) at the center of the prism is reduced.

  FIG. 3 is a diagram showing that the F value of the light beam 15 is changed by the concave lens 272a. In the case of the first embodiment shown in FIGS. 1 and 2, the F value of the light beam 15 passing through the prism is approximately 2.0, but the F value is 1 by spreading the light beam like the light beam 15a by the concave lens 272a. .7, and the illuminance ratio on the screen due to kicking at the central portion 57d of the prism is reduced from about 3% to about 1%, which is reduced to an extent that cannot be visually recognized.

  FIG. 4 is a diagram showing a second embodiment of the prism of the present invention. 2 differs from the first embodiment of FIG. 2 in that the exit surface 274a is not a convex lens but a flat surface. In the second embodiment, the red light beam incident surface 271a, the green light beam incident surface 272a, and the blue light beam incident surface 273a are configured as concave lenses as in the first embodiment. The color-synthesized light exit surface 274a is a flat surface with unevenness of one wavelength or less. When the projection display device is configured using the prism of the second embodiment, the convex lens action on the light exit surface of the prism of the first embodiment shown in FIG.

  Hereinafter, FIGS. 5 to 11 will be described with respect to third to ninth embodiments of the prism of the present invention. The third to ninth embodiments relate to a technique for bonding triangular prisms.

  FIG. 5 is a diagram showing a third embodiment of the prism of the present invention.

In FIG. 5, the prism includes four triangular prisms 271, 272, 273, and 274 whose base material is a plastic material. In the triangular prism 271, a red reflecting film 27 r is formed on the 271 b surface, and a SiO ₂ (silicon dioxide) single layer film 27 s having a thickness of about 10 nm is formed on the 271 c surface. In the triangular prism 272, a SiO ₂ single layer film 27s having a thickness of about 10 nm is formed on both surfaces of the 272b surface and the 272c surface. In the triangular prism 273, a blue reflecting film 27b is formed on the 273c surface, and a SiO ₂ single layer film 27s having a thickness of about 10 nm is formed on the 273b surface. The triangular prism 274 has a blue reflective film 27b formed on the 274b surface and a red reflective film 27r formed on the 274c surface. The first and final layers of the blue reflective film 27b and the red reflective film 27r are SiO ₂ layers. The four triangular prisms 271, 272, 273, and 274 are bonded by an adhesive 27g. A thin film (SiO ₂ single layer film) 27s is formed between the adhesive 27g and the triangular prism prism surface, and the plastic material which is the triangular prism prism base material is brought into close contact with the SiO ₂ single layer film. Also, the adhesive is brought into close contact with the SiO ₂ single layer film, so that the four triangular prisms 271, 272, 273, and 274 are bonded (bonded) to each other. The prism having such a configuration was subjected to a temperature cycle test in a range of approximately −30 ° C. to + 70 ° C., and the adhesive strength (bonding strength) was measured. As a result, a strength of approximately 200 N or more was obtained.

  FIG. 6 shows a fourth embodiment of the prism of the present invention.

  The fourth embodiment is a configuration example when there is no single layer film on the 272c surface, that is, when a thin film is formed on seven of the eight bonding surfaces. As a result of actual measurement, also in the fourth example, the adhesive strength of about 200 N or more was obtained between the four triangular prisms.

7-10 is a figure which shows the 5th-8th Example of the prism of this invention. In any case, the combination of the positions of the red reflective film 27r, the blue reflective film 27b, and the SiO ₂ single layer film 27s is changed with respect to the configuration of the third embodiment of FIG.

FIG. 7 shows a fifth embodiment of the prism of the present invention. A SiO ₂ single layer film 27s is formed on the 271c surface of the triangular prism 271, a red reflecting film 27r is formed on the 271b surface, and a SiO ₂ single layer film 27s is formed on the 272c surface of the triangular prism 272. The blue reflection film 27b is formed on the 272b surface, the SiO ₂ single layer film 27s is formed on the 273c surface of the triangular prism 273, the red reflection film 27r is formed on the 273b surface, and the 274c surface of the triangular prism 274 is formed. A SiO ₂ single layer film 27s is formed on the surface, and a blue reflective film 27b is formed on the surface 274b.

FIG. 8 shows a sixth embodiment of the prism of the present invention. The SiO ₂ single layer film 27s is formed on the 271c and 271b surfaces of the triangular prism 271, the red reflecting film 27r is formed on the 272c surface of the triangular prism 272, and the blue reflecting film 27b is formed on the 272b surface. The SiO ₂ single layer film 27s is formed on the 273c and 273b surfaces of the triangular prism 273, the red reflecting film 27r is formed on the 274c surface of the triangular prism 274, and the blue reflecting film 27b is formed on the 274b surface. ing.

FIG. 9 shows a seventh embodiment of the prism of the present invention. The 271c faces of triangular prisms 271 is formed SiO ₂ single layer 27s, the 271b face the red reflecting film 27r is formed, the SiO ₂ single layer film 27s to 272c face and 272b face of triangular prisms 272 The blue reflecting film 27b is formed on the 273c surface of the triangular prism 273, the SiO ₂ single layer film 27s is formed on the 273b surface, and the red reflecting film 27r is formed on the 274c surface of the triangular prism 274. A blue reflective film 27b is formed on the surface 274b.

FIG. 10 shows an eighth embodiment of the prism of the present invention. The 271c faces of triangular prisms 271 is formed SiO ₂ single layer 27s, the 271b face the red reflecting film 27r is formed, the SiO ₂ single layer film 27s to 272c face and 272b face of triangular prisms 272 The blue reflecting film 27b is formed on the 273c surface of the triangular prism 273, the SiO ₂ single layer film 27s is formed on the 273b surface, and the red reflecting film 27r is formed on the 274c surface of the triangular prism 274. A blue reflective film 27b is formed on the surface 274b.

7 to 10, the same parts as those in FIGS. 5 and 6 are denoted by the same reference numerals. For both examples, the red reflecting film 27r is a dielectric multilayer film, a blue reflective film 27b is SiO ₂ first layer and the last layer having a red reflecting properties to form a first layer and last layer of SiO ₂ The dielectric multilayer film formed and having a blue reflection characteristic, the SiO ₂ single layer film 27s, is a thin film having a thickness of about 10 nm. Monolayer film 27s, instead of SiO _2, may be formed of SiO refractive index substantially 1.55 to 1.65 (silicon monoxide). Further, when a single layer film made of a mixed material of SiO ₂ and aluminum oxide having a refractive index of about 1.48 to 1.54 is used instead of SiO ₂ , the interface reflectance between the plastic material and the single layer film is The range can be approximately 0.005% or less.

FIG. 11 shows a ninth embodiment of the prism of the present invention. This embodiment is an example of a prism that forms a film (polarized light separation film) having selectivity for polarized light as a light selective film and separates incident light into two types of polarized light. An S-polarized light reflecting film 30p is formed on the 301c surface of the triangular prism 301, and an SiO ₂ single layer film 30s having a thickness of about 10 nm is formed on the 302c surface of the triangular prism 302. 30 g is an adhesive. The light (light beam 8) incident from the incident surface 301a is reflected by the S-polarized light reflecting film 30p and emitted from the surface 301b. On the other hand, the P-polarized light passes through the S-polarized light reflecting film 30p and is emitted from the surface 302a. In this way, the incident light beam 8 is separated into S-polarized light 8s and P-polarized light 8p. As a projection type display device configuration using this prism, for example, white light from the light source 1 side is aligned with S-polarized light or P-polarized light with this prism, and the aligned polarized light is red light and green light with a dichroic mirror. The color light is separated into blue light, the separated color light is modulated based on image information by a liquid crystal panel or the like, the modulated color lights are synthesized by a color synthesis prism, and the synthesized light is projected by a projection lens unit or the like. The light is incident on the means. The liquid crystal panel or the like is driven by a drive circuit based on image information. The projecting means enlarges and projects the combined light on the screen.

Next, an example of the manufacturing method of the prism of this invention is demonstrated. For example, a cycloolefin resin is used for each triangular prism. The cycloolefin resin has a glass transition point under atmospheric pressure of 139 ° C. (when measured by the DSC (Differential Scanning Calorimetry method) method) and an excessive deflection temperature of 122 ° C. (ASTM (American Society for Testing and Material) when measured with D648). The triangular prisms are manufactured by injection compression molding (injection molding and compression) using an injection compression mold having a core compression mechanism. For example, the compression is performed by applying pressure to the movable portion provided on the surfaces of the triangular prisms 271a, 272a, 273a, and 274a. Specifically, for example, the mold temperature is set to about 130 ° C. to 135 ° C., molten resin of about 250 ° C. to 300 ° C. is injected and filled, and after holding pressure is applied to the gate portion, the core The compression part is compressed by applying a pressure of about 0.8 × 10 ⁵ N / m ^{2 to} 1.0 × 10 ⁵ N / m ² and maintained in that state for 5 minutes or more. Then, the molded product is taken out in the air. Cool naturally to room temperature. Next, the molded article is heated to a temperature lower by 10 ° C. to 20 ° C. than the glass transition point and held for a certain period of time, and then annealed to cool to room temperature. As an example, it is heated to approximately 125 ° C. and held at this temperature for approximately 12 hours or more, and then approximately 125 ° C. to 100 ° C. at a rate of approximately 0.2 ° C./min to 0.4 ° C. Cool and cool to approximately 100 ° C. to 60 ° C. at a rate of approximately 1.0 ° C./min. Then, it is naturally cooled to room temperature in air.

Next, a dichroic film is formed on the triangular prisms manufactured as described above. As the dichroic film, a red reflection film having red reflection characteristics and a blue reflection film having blue reflection characteristics are formed. In these dichroic films, for example, an SiO ₂ film having a refractive index in the range of about 1.43 to 1.47 at a measurement wavelength of about 550 nm is formed in the first layer, and a TiO ₂ (titanium dioxide) film and SiO ₂ are formed in the second and subsequent layers. The films are alternately formed, the layer before the final layer is a TiO ₂ film, the final layer is the same SiO ₂ film as the first layer, and has a multi-layer structure composed of an odd number of 15 or more layers. When the dichroic film of the prism of FIGS. 5 and 6 is formed, the triangular prisms 271 and 274 are combined so that the 271b surface and the 274c surface become one plane, and further, at the apex position of the triangle of each triangular prism. The formed ridge lines are combined so that there is no gap between them. Thereafter, red reflecting dichroic films are formed on the 271b surface and the 274c surface. Next, in the same manner as described above, triangular prisms 273 and 274 are combined to form a blue reflecting dichroic film on the 273c surface and the 274b surface. Similarly, in the case of the configuration of FIG. 7, the triangular prisms 271 and 273 are combined to form red reflecting dichroic films on the 271b surface and the 273b surface. Triangular prisms 272 and 274 are similarly combined to form a blue reflecting dichroic film on the 272b and 274b surfaces. Similarly, in the case of the configuration of FIG. 8, triangular prisms 272 and 274 are combined to form blue reflective dichroic films on the 272b and 274b surfaces, and red reflective dichroic films on the 272c and 274c surfaces. After forming the red reflective dichroic film and the blue reflective dichroic film, an SiO ₂ film is formed to a thickness of approximately 10 nm. As a result of the experiment, when the thickness of the SiO ₂ film is thicker than about 20 nm in the configurations of FIGS. 5 to 10, the interface reflection of the transmitted light at the interface with the triangular prism material or the interface with the adhesive increases. The adhesion strength with the triangular prism material may decrease. On the contrary, when the thickness of the SiO ₂ film is thin and approximately 5 nm or less, there may be a place where the film is not formed when the film thickness unevenness occurs. Accordingly, the appropriate thickness of the SiO ₂ film is approximately 10 nm ± 5 nm.

  Next, four triangular prisms are bonded. Specifically, a visible light curable adhesive is applied between the triangular prisms 273 and 274 and held on a jig, and the adhesive is cured by irradiating blue light having a wavelength of about 400 nm to 480 nm. Similarly, a visible light curable adhesive is applied between the triangular prisms 271 and 272, and the adhesive is cured by irradiating blue light. Visible light for curing is incident on the adhesive from the single-layer film side. Further, a visible light curable adhesive is applied between the triangular prisms 273 and 274 and the triangular prisms 271 and 272, and fixed to a jig, respectively. After adjusting the apex angles of the four triangular prisms to be aligned at one point, the adhesive is cured by irradiating blue light. The visible light for curing is irradiated uniformly from four directions.

  One prism is completed through the above steps.

According to the technique of the above embodiment, the concave lens on the light incident surface of the prism enlarges the light beam cross-sectional area of the incident light in the prism, and reduces the proportion of the light beam blocked by the ridgeline at the center of the prism. It is possible to reduce vertical stripe-shaped luminance unevenness generated on the screen due to the configuration of the part. Further, the convex lens on the light exit surface of the prism reduces the light beam cross-sectional area, emits it from the prism as the combined light in a focused state, and makes it incident on the projection lens unit, so that the burden of light focusing in the projection lens unit can be reduced, The lens unit can be reduced in size and cost. In addition, the single-layer film such as SiO _{2 in the} bonded portion is formed of a plastic material or the like in order to improve adhesion of the adhesive layer on the surface of the triangular prism (prism piece). Even in this case, peeling of the adhesive layer based on thermal expansion or the like can be prevented.

  In the above embodiment, the triangular prism prism material is a cycloolefin resin. However, the material is not limited to this, and a transparent thermoplastic resin such as an acrylic resin or a polycarbonate resin may be used. Further, in the above-described embodiment, an example of a configuration using a transmissive liquid crystal panel has been described. However, the present invention is not limited to this, and a configuration using a reflective liquid crystal panel may be used, or a liquid crystal panel may be used. Other display panels than the above, for example, DMD (Digital Micromirror Device) (registered trademark of Texas Instruments) may be used. For example, in the case of a projection display device using a reflective panel, a cross dichroic prism (color combining prism) is used as a color light separating unit that separates light into three color lights of red, green, and blue. It is also used as color light combining means for combining red light, green light, and blue light modulated in accordance with image signals on the panel and emitting them again.

  In addition, in the invention related to the invention described in the claims, the invention described in the above embodiment includes (1) a structure in which the thickness of the single layer film of the bonded portion of the prism is set to approximately 20 nm or less (2) As a configuration of the bonding portion of the prism, the first layer in contact with the triangular prism (prism piece) of the dichroic multilayer film that reflects at least either red light or blue light is SiOx (x is 1 to 2). And (3) the first layer in contact with the triangular prism of the dichroic multilayer film that reflects at least either red light or blue light, and an adhesive, The last layer in contact is composed of SiOx (x is a number including a decimal point from 1 to 2). (4) Four triangular prisms are bonded to form one prism, and the four triangular prism prisms A structure in which a thin film is provided between the adhesive layer and the prism surface in seven of the eight bonded portions between the two members. (5) As a method of manufacturing the prism piece from a plastic material, an injection molded prism piece is used. There is a step of performing an annealing process of heating to a temperature 10 ° C. to 20 ° C. lower than the glass transition point and holding it for a certain period of time, followed by cooling to room temperature.

It is a figure which shows the structural example of the projection type display apparatus as an Example of this invention. It is a figure which shows the 1st Example of the prism of this invention. It is explanatory drawing of the effect | action in the light-incidence surface of the prism of 1st Example. It is a figure which shows the 2nd Example of the prism of this invention. It is a figure which shows the 3rd Example of the prism of this invention. It is a figure which shows the 4th Example of the prism of this invention. It is a figure which shows the 5th Example of the prism of this invention. It is a figure which shows the 6th Example of the prism of this invention. It is a figure which shows the 7th Example of the prism of this invention. It is a figure which shows the 8th Example of the prism of this invention. It is a figure which shows the 9th Example of the prism of this invention. It is a perspective view of the conventional prism. It is a cross-sectional enlarged view of a conventional prism. It is a figure which shows the structural example of the conventional projection type display apparatus. It is a top view of the conventional prism. It is a figure which shows the example of the illuminance ratio characteristic in the screen surface of the prism central part in the conventional prism, and its adjacent part. It is a figure which shows the ridgeline width | variety (delta) in the center part of a triangular prism. It is a figure which shows the shift | offset | difference when a triangular prismatic prism is bonded together.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Light source, 2 ... Reflector, 3 ... White light beam, 4 ... 1st lens array, 5 ... Cold mirror, 6 ... 2nd lens array, 7 ... Blue and green reflective dichroic mirror, 8 ... Red light beam, 9 ... Increase reflection Mirror, 10, 16, 24 ... condenser lens, 12 ... red-light transmissive liquid crystal panel, 13 ... green / blue light beam, 14 ... green reflective dichroic mirror, 15 ... green light beam, 17 ... deflector plate, 18 ... for green light Transmission liquid crystal panel, 19 ... blue light beam, 20 ... relay lens, 21 ... increasing reflection mirror, 22 ... relay lens, 23 ... increasing reflection mirror, 26 ... transmission liquid crystal panel for blue light, 27 ... prism, 27r ... red reflection Film, 27b ... Blue reflective film, 27s, 30s ... Single layer film, 274, 301, 302 ... Triangular prism, 271a ... Red light beam incident surface, 271b, 274c ... Red light Reflective dichroic mirror surface, 272a... Green light beam incident surface, 273a... Blue light beam incident surface, 273c, 274b... Blue light beam reflecting dichroic mirror surface, 274a. ... Adhesive, 30p ... S-polarized reflection film, 60 ... Input terminal, 70 ... Drive circuit, 80 ... Power source circuit for light source.

Claims (18)

A prism that separates colored light from incident light or synthesizes and emits a plurality of colored lights,
A prism characterized in that a concave lens is formed on a light incident surface. A prism that separates colored light from incident light or synthesizes and emits a plurality of colored lights,
A prism having a concave lens formed on a light incident surface and a convex lens formed on a light emitting surface.   3. The prism according to claim 1, wherein the light incident surface has a concave lens formed on each color light incident surface of red light, green light, and blue light. 4. A prism that separates colored light from incident light or synthesizes and emits a plurality of colored lights,
A plurality of triangular prisms are bonded together,
A prism in which a thin film is provided between an adhesive layer and a prism surface in all or a part of the bonded portion.   5. The prism according to claim 4, wherein one of the thin films is a single layer film, and the other is a multi-layer film reflecting a specific color light. Four triangular prisms are used,
A multilayer film that reflects specific color light is formed in four of the eight bonded portions,
The prism according to claim 4, wherein a single layer film is formed in the other four bonding portions. Four triangular prisms are used,
A multilayer film that reflects specific color light is formed in four of the eight bonded portions,
The prism according to claim 4, wherein a single layer film is formed in the other three bonded portions. The prism according to claim 5, 6 or 7, wherein the single-layer film is SiOx (x is a number including a decimal point of 1 to 2) or a mixed material of SiO ₂ and aluminum oxide. The prism according to claim 8, wherein the mixed material of SiO ₂ and aluminum oxide has a light refractive index in a range of about 1.48 to 1.54.   The prism according to any one of claims 5 to 9, wherein the multilayer film includes a layer of SiOx (x is a number including a decimal point of 1 to 2).   The prism according to claim 4, wherein the triangular prism is made of a plastic material. An optical unit for a projection display device,
A panel that modulates the separated color light based on image information;
A concave lens is formed on the light incident surface, and a prism for color-combining modulated light from the panel incident through the concave lens portion;
An optical unit comprising projection means for enlarging and projecting the color-synthesized light on a screen. An optical unit for a projection display device,
A panel that modulates the separated color light based on image information;
A concave lens is formed on the light incident surface, and a convex lens is formed on the light output surface, and a prism that color-synthesizes the modulated light from the panel that is incident through the concave lens portion and emits the light from the convex lens portion;
An optical unit comprising projection means for enlarging and projecting the emitted color composite light on a screen. An optical unit for a projection display device,
A panel that modulates the separated color light based on image information;
A plurality of triangular prisms are bonded together, and a dichroic thin film or single-layer thin film is provided between the adhesive layer and the prism surface in all or part of the bonded portion, and color modulation of the modulated light from the panel is performed. And the exiting prism,
An optical unit comprising projection means for enlarging and projecting the color-synthesized light on a screen. The optical unit according to any one of claims 12 to 14,
A driving circuit for driving the panel;
A projection display device comprising: a power supply circuit for driving a light source. A method of manufacturing a prism,
A step of injection-molding the prismatic prism with plastic;
Holding the molded product in a temperature range of a predetermined range for a predetermined time;
Then the cooling step;
Forming a first reflective film;
Forming a single layer film and attaching a triangular prism;
Forming a second reflective film and bonding the triangular prisms;
A prism manufacturing method characterized by manufacturing a prism through A prism that separates incident light into different kinds of polarized light,
A plurality of triangular prisms are bonded together,
A thin film is provided between the adhesive layer and both prism surfaces in the bonding portion,
The prism is characterized in that one of the thin films is a single layer film and the other is a polarized light separating film having selectivity for polarized light. A prism according to claim 17;
A panel that modulates the separated color light based on image information;
A drive circuit for driving the panel;
A projection display device comprising: a projection unit that enlarges and projects color-synthesized light on a screen.

Images