JP2008176097A - Projector and projector manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a projector and a projector manufacturing method where such a failure is prevented that the optical performance adjustment performed once at a manufacturing process comes to nothing. <P>SOLUTION: Regarding the optical unit 1 integrally constituted by assembling respective optical components in corresponding positions on the top surface of a metallic base 8 functioning as a base, the optical unit 1 finishing the adjustment of the optical performance thereof is attached to a case by fixing the optical unit 1 to the case bottom part of the projector by screwing through the screw hole 8c of the base 8. In this case, the base 8 is formed of metal, then, the base 8 is not distorted by stress applied when attaching even if dimensional variation occurs in terms of respective fixing parts 12, consequently, the deterioration in the optical performance of the optical unit 1 is prevented. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a projector and a projector manufacturing method for improving production efficiency.

In a projector that projects an image signal input from a personal computer or the like as image light onto a screen, the mounting accuracy of optical components such as a light source, a projection lens, a prism, and a mirror greatly affects the optical performance. Patent Document 1 proposes a projector that suppresses a decrease in luminance of lamp light due to misalignment by providing a cylindrical portion with a retaining member on a casting so as to correspond to three positioning bosses provided on a lamp case. ing. Patent Document 2 proposes a projector that facilitates positioning and fixing by integrally forming, on one of the light guides, a member that urges the lens toward the other light guide.
JP 2005-43603 A JP 2002-350978 A

  However, the optical performance may eventually deteriorate in the assembly process even though the optical component is attached by accurate positioning. In the general projector manufacturing process shown in FIG. 6, as shown in FIG. 5, first, a color separation system and a relay optical system including a lamp unit 25, a projection lens unit 22, a prism unit (not shown), a dichroic mirror, and the like. The optical parts such as the main body unit 23 and the light guide unit 24 having the rod integrator are individually assembled (st1). Next, the lamp unit 25, the projection lens unit 22, the prism unit, the light guide unit 24, and the like are assembled to the main body unit 23 using the attachment members 35 and 36, and the optical unit 21 is integrally configured (st2). Here, when there is a problem in optical performance due to variations in optical components, the optical performance is adjusted by performing position adjustment such as processing of the components (st3). Thereafter, the adjusted optical unit 21 is attached to the bottom of the case 31 of the projector 11 (st4). Here, the optical unit 21 is fixed by screwing the attachment members 35 and 36 and the fixing portion 32 provided in the case 31.

  At this time, a lot of plastic molded parts are used for each optical part, and the case 31 is also molded of plastic. If the dimensional variation of the mounting members 35 and 36 or the fixing portion 32 is large, the optical parts are attached. Sometimes stress is applied to the component, and the component may be distorted and deviate from the original mounting position. For example, as shown in FIG. 6, if the dimensional accuracy of the attachment member 36 is poor, the projection lens unit 22 is distorted downward (see the dotted line in FIG. 6). In such a case, it is necessary to adjust the optical performance (st5) again, which causes a reduction in the production efficiency of the projector 20.

  SUMMARY An advantage of some aspects of the invention is to provide a projector and a projector manufacturing method in which adjustment of optical performance once performed in the manufacturing process is not wasted.

  In order to solve the above problems, a projector according to the present invention includes an optical component including a light source, a projection lens, a prism, and a mirror inside a case, and the optical component is assembled to an upper surface of a metal base so as to be integrated. The constructed optical unit is attached by fixing the base to the bottom of the case.

  Further, the projector manufacturing method of the present invention includes an optical component assembling step for assembling optical components each including a light source, a projection lens, a prism, and a mirror, and an optical unit integrally assembled by assembling the optical components on the upper surface of a metal base. An optical unit assembling step to be configured; a performance adjusting step of adjusting the optical performance of the optical unit; and an optical unit attaching step of fixing the base to the bottom of the case and attaching the optical unit.

  Since the optical unit is constructed by assembling the optical component on the upper surface of the metal base, the optical unit is not distorted when the projector is attached to the case, and the adjusted optical performance can be maintained. Accordingly, it is not necessary to readjust the optical performance, and the production efficiency of the projector is improved.

  As shown in FIGS. 1 and 2, the optical unit 1 of the present invention is integrally configured by assembling each optical component at a corresponding position on the upper surface of a base 8 serving as a base. The base 8 is formed by processing a metal such as aluminum into a shape that matches the optical component and the main body case to be attached. The base 8 is provided with screw holes 8a for assembling optical components and positioning bosses 8b, and further, screw holes 8c for attaching to the bottom of the main body case are also provided as appropriate.

  The lamp unit 5 includes a lamp that is a light source and a reflector that reflects the illumination light of the lamp toward the light guide unit 4. As the lamp, a lamp having sufficient luminance such as a mercury lamp or a metal halide lamp is generally used. In addition, a screw hole 5a and a positioning boss hole 5b are provided at the lower part of the lamp unit 5 to be attached to the corresponding positions of the base 8 with screws.

  The light guide unit 4 is a rod integrator that illuminates the main body unit 3 with uniform illumination light incident by a small lens group. A screw hole 4 a is provided at a lower portion of the light guide unit 4 to be attached to a corresponding position of the base 8 with a screw.

  The main unit 3 includes a polarization conversion element provided at the entrance of the illumination light from the light guide unit 4, and the illumination light transmitted therethrough is converted into S-polarized light. Further, the illumination light is separated into light of three colors of red, green and blue by a plurality of dichroic mirrors provided along the optical path inside the main body unit 3, and from each corresponding irradiation opening on the inner side surface. The light enters the prism unit 6. Note that a screw hole 3a and a positioning boss hole 3b are provided at the lower portion of the main unit 3 to be attached to the corresponding positions of the base 8 with screws.

  The prism unit 6 includes a liquid crystal panel at an entrance of illumination light separated into three colors, and the illumination light is provided with image information corresponding to each color. Here, a signal obtained by separating an image signal input from the outside into three colors is input to the liquid crystal panel. In addition, the prism unit 6 is provided with a plurality of prisms surrounded by three liquid crystal panels, and the separated three colors of light are transmitted through the prism and projected from the irradiation port as one image light. The light enters the lens unit 2. The prism unit 6 is attached to an installation base 8d provided in front of the base 8 in order to align the height position with the projection lens unit 2. Here, the lower part of the prism unit 6 is provided with a screw hole 6a and a positioning boss hole 6b for mounting with screws at corresponding positions of the installation base 8d.

  The projection lens unit 2 enlarges and projects image light onto a screen installed in front of the projector. The projection lens unit 2 is attached to the front of the base 8 via a substantially U-shaped lens mount 7 made of metal. Screw holes 2 a corresponding to the screw holes 7 a provided in the lens mount 7 are provided on both sides of the projection lens unit 2. In addition, screw holes 7b and screw holes 7c for positioning are provided on both side portions of the lens mount 7 at the corresponding positions of the base 8 with screws. The lens mount 7 may be formed integrally with the base 8.

  The optical unit 1 configured as described above is inspected for optical performance after assembling, and the optical performance is adjusted when the standard performance is not satisfied due to variation in the dimensions of the optical components or mounting failure. Examples of the adjustment means include adjustment of the position of the optical component and processing.

  The optical unit 1 whose optical performance has been adjusted is provided at the bottom of the case 11 by a screw 13 via a screw hole 8c of the base 8 as shown in a cross-sectional portion along the line V in FIG. , It is attached to the case 11 by being fixed to the corresponding fixing part 12. Here, since the base 8 is made of metal, for example, even if the dimensions of the respective fixing portions 12 vary, the base 8 is not distorted by the stress applied at the time of attachment. Therefore, the optical unit 1 can be attached to the case 11 without deteriorating its optical performance.

  The manufacturing process of the projector 10 provided with such an optical unit 1 is roughly as shown in FIG. First, optical components such as the projection lens unit 2 and the main unit 3 are individually assembled (st1). Next, each optical component is assembled to the base 8 with a screw (st2). The optical unit 1 thus formed is optically adjusted as necessary as described above (st3). Finally, by screwing the base 8 to the case 11, the attachment of the optical unit 1 to the case 11 is completed, and the projector 10 is completed (st4). By such a manufacturing method of the projector 10, the optical performance of the optical unit 1 is not deteriorated when the optical unit 1 is finally attached, so that the adjustment of the optical performance performed previously is not wasted and the production efficiency of the projector is improved. can do. Note that the configuration and form of the optical component shown in the present embodiment are not limited to this, and are appropriately determined according to the design. The same applies to the shape of the base 8 and the number and positions of the screw holes 8a and the bosses 8b.

It is a disassembled perspective view which shows an example of the optical unit of this invention. It is a top view which shows an example of the optical unit of this invention. It is sectional drawing of the side which shows an example of the projector of this invention. It is a flow which shows the projector manufacturing method of this invention. It is a flow which shows the conventional projector manufacturing method. It is side sectional drawing which shows an example of the conventional projector.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1,21 Optical unit 2,22 Projection lens unit 3,23 Main body unit 4,24 Light guide unit 5,25 Lamp unit 6 Prism unit 7 Lens mount 8 Base 10 Projector 11 Case 12, 32 Fixing part 35, 36 Attachment member

Claims (2)

In a projector provided with optical components including a light source, a projection lens, a prism, and a mirror inside the case,
An optical unit integrally configured by assembling the optical component on an upper surface of a metal base is attached by fixing the base to the bottom of the case. Optical component assembly process for assembling optical components including a light source, a projection lens, a prism, and a mirror,
An optical unit assembling step for assembling an optical unit integrally by assembling the optical component on an upper surface of a metal base;
A performance adjustment step of adjusting the optical performance of the optical unit;
An optical unit attaching step for attaching the optical unit while fixing the base to the bottom of the case.

Images