JP2010224225A - Method for manufacturing optical device, and projector - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing an optical device, the method improving contrast of a projection image, and to provide a projector. <P>SOLUTION: The optical device includes: a plurality of optical modulators which modulate a plurality of color light beams in accordance with image information for each color light beam; a cross dichroic prism which has a plurality of light-incident surfaces opposed to the respective optical modulators, and forms an image by combining the respective color light beams modulated by the respective optical modulators; and a first polarizing plate and an emitting-side polarizing plate which are disposed between the optical modulator and the light-incident surface. The method of manufacturing the optical device includes: an optical element-fixing step S2 of fixing the first polarizing plate and the emitting-side polarizing plate on the light-incident surface; and an optical modulator-fixing step S4 of fixing the optical modulator on the light-incident surface after the optical element-fixing step S3. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to an optical device manufacturing method and a projector.

Conventionally, an optical apparatus having a plurality of light modulation devices that modulate light beams emitted from a light source according to image information, and a color combining optical device that forms image light by combining light beams modulated by the light modulation devices. A projector is known that includes a projection lens that magnifies and projects formed image light.
In such a projector, a plurality of optical elements that optically convert an incident light beam are interposed between the light modulation device and the color synthesis optical device (see, for example, Patent Document 1).
In the projector described in Patent Document 1, on the light emission side of the light modulation device, a viewing angle compensation plate (optical element) held by a holding member that holds the light modulation device, and an emission fixed to the color synthesis optical device. A side polarizing plate (optical element) is provided. Accordingly, the holding member is fixed to the color synthesizing optical device to which the emission side polarizing plate is attached while holding the light modulation device and the viewing angle compensation plate.

JP 2008-225168 A

  However, in the projector described in Patent Document 1, when the holding member is positioned on the color synthesis optical device, the mounting angle of the viewing angle compensation plate held by the holding member is shifted by adjusting the position of the light modulation device. Will end up. Thereby, there exists a problem that the contrast of the projection image projected from a projection lens falls.

  An object of the present invention is to provide an optical device manufacturing method and a projector that can prevent a decrease in contrast of a projected image.

  The method of manufacturing an optical device according to the present invention includes a plurality of light modulation devices that modulate a plurality of color lights according to image information for each color light, and a plurality of light incident surfaces facing the light modulation devices. Production of an optical apparatus comprising a color synthesizing optical device that forms an image by synthesizing each color light modulated by a modulation device, and a plurality of optical elements disposed between the light modulation device and the light incident surface An optical element fixing step for fixing the plurality of optical elements to the light incident surface, and an optical modulation for fixing the light modulation device to the light incident surface after the optical element fixing step. An apparatus fixing step.

  In the present invention, first, a plurality of optical elements are fixed to the light incident surface of the color synthesizing optical device, and then the light modulation device is fixed to the light incident surface. According to this, since the plurality of optical elements are fixed to the light incident surface in advance, for example, even when the position adjustment (alignment adjustment, focus adjustment) of the light modulation device is performed thereafter, the plurality of optical elements are arranged. Since these optical elements are fixed to each other and fixed to the color synthesizing optical device, the mounting angle between the optical elements does not shift. Accordingly, it is possible to prevent a decrease in the contrast of the projected image due to a shift in the mounting angle of the plurality of optical elements.

  The projector according to the present invention includes a plurality of light modulation devices that modulate a plurality of color lights according to image information for each color light, and a plurality of light incident surfaces that face the light modulation devices. A projector comprising: a color synthesis optical device that synthesizes each modulated color light to form an image; and a plurality of optical elements disposed between the light modulation device and the light incident surface. The first optical element fixed to the incident surface, the other optical element disposed on the light incident side of the first optical element, and the first optical element in a state of being separated from the first optical element. A first support member that supports another optical element and supports the other optical element in a state of being separated from each other, and a second support member that is fixed to the light incident surface and supports the light modulation device It is characterized by providing.

Here, the configuration as the “first optical element fixed to the light incident surface” includes a configuration in which the light incident surface and the first optical element are fixed via a translucent member or the like. It is a waste.
Further, the configuration as the “second support member fixed to the light incident surface” includes a configuration in which a member is fixed between the light incident surface and the second support member.
In the present invention, since the first optical element and the other optical elements or the other optical elements are supported by the first support member in a state of being separated from each other, the respective optical elements are mutually connected via the first support member. I can support it.
That is, a plurality of optical elements can be supported in advance in a state of being separated via the first support member. The light modulation device is supported by the second support member, and the second support member is fixed to the light incident surface. When fixing the light modulation device, alignment adjustment and focus adjustment are necessary, but even when these adjustments are performed, the plurality of optical elements do not cause a shift in the mounting angle. A reduction in the contrast of the projected image can be prevented.

1 is a diagram schematically illustrating a schematic configuration of a projector according to an embodiment of the invention. The perspective view which shows a part of optical device. The disassembled perspective view of the said optical apparatus. The perspective view which shows the state by which the exit side polarizing plate was attached to the cross dichroic prism. 6 is a flowchart showing a method for manufacturing the optical device.

Hereinafter, an embodiment according to the present invention will be described with reference to the drawings.
[Projector configuration]
FIG. 1 is a diagram schematically illustrating a schematic configuration of the projector 1.
The projector 1 forms an image according to image information and projects it on a screen (not shown). As shown in FIG. 1, the projector 1 includes a substantially rectangular parallelepiped outer casing 2, a projection lens 3 as a projection optical device, an optical unit 4, and a power source that supplies power to each component inside the projector 1. A unit 5, a cooling fan 6 that cools each component inside the projector 1, and a control device that controls each component inside the projector 1, although not specifically shown, are provided.

The exterior housing 2 has a substantially rectangular parallelepiped shape as a whole, and is formed of a synthetic resin in this embodiment. The exterior casing 2 includes an upper case that configures the top, front, back, and side surfaces of the projector 1 and a lower case that configures the bottom, front, back, and side surfaces of the projector 1. Each case is fixed to each other with a screw or the like. In addition, the exterior housing | casing 2 may be formed with not only a synthetic resin etc. but with another material, for example, you may comprise with a metal etc.
The projection lens 3 is configured as a combined lens obtained by combining a plurality of lenses, and enlarges and projects the image light formed by the optical unit 4 on the screen.

  The optical unit 4 optically processes the light beam emitted from the light source to form image light corresponding to the image information under the control of the control device. As shown in FIG. 1, the optical unit 4 includes a light source device 41, an illumination optical device 42, a color separation optical device 43, a relay optical device 44, an optical device 45, and a light beam emitted from the light source device 41. The optical component casing 46 accommodates the optical components 41 to 45 described above at a predetermined position with respect to the illumination optical axis A set inside.

As shown in FIG. 1, the light source device 41 includes a light source 411, a reflector 412 and the like.
Then, the light source device 41 emits the light beam emitted from the light source 411 toward the illumination optical device 42 with the light emission direction aligned by the reflector 412.

  As shown in FIG. 1, the illumination optical device 42 includes a first lens array 421, a second lens array 422, a polarization conversion element 423, and a superimposing lens 424. The light beam emitted from the light source device 41 is divided into a plurality of partial light beams by the first lens array 421 and forms an image in the vicinity of the second lens array 422. Each partial light beam emitted from the second lens array 422 is incident so that its central axis (principal ray) is perpendicular to the incident surface of the polarization conversion element 423, and the polarization conversion element 423 emits approximately one type of linearly polarized light. Injected as light. A plurality of partial light beams emitted from the polarization conversion element 423 as linearly polarized light and passed through the superimposing lens 424 are superimposed on three light modulation devices 451 described later of the optical device 45.

As shown in FIG. 1, the color separation optical device 43 includes two dichroic mirrors 431 and 432 and a reflection mirror 433, and the dichroic mirrors 431 and 432 and the reflection mirror 433 emit the light from the illumination optical device 42. It has a function of separating a plurality of partial light beams into three color lights of red, green, and blue.
As shown in FIG. 1, the relay optical device 44 includes an incident side lens 441, a relay lens 443, and reflection mirrors 442 and 444, and the color light separated by the color separation optical device 43, for example, red light, is supplied to the optical device 45. Has a function of guiding to a light modulation device 451R on the red light side described later.

The optical device 45 modulates an incident light beam according to image information to form image light. As shown in FIG. 1, the optical device 45 includes three light modulation devices 451 (red light side light modulation device 451R, green light side light modulation device 451G, and blue light side light modulation device 451B. ), An incident side polarizing plate 452 disposed on the light incident side of each light modulation device 451, a first polarizing plate 453 as another optical element disposed on the light emission side of each light modulation device 451, An emission-side polarizing plate 454 as a first optical element and a cross dichroic prism 455 as a color synthesis optical device are provided.
The detailed configuration of the optical device 45 will be described later.

The three incident-side polarizing plates 452 transmit only polarized light having substantially the same polarization direction as the polarization direction aligned by the polarization conversion element 423 among the light beams separated by the color separation optical device 43, and other light beams. The polarizing film is affixed on the translucent substrate. The three incident-side polarizing plates 452 are configured separately from the other components of the optical device 45.
The three first polarizing plates 453 transmit polarized light in a predetermined direction among the light beams emitted through the light modulation device 451 and partially absorb the other light beams.
The three exit-side polarizing plates 454 have substantially the same function as the incident-side polarizing plate 452 and transmit only polarized light in a predetermined direction among the light beams transmitted through the first polarizing plate 453 and absorb other light beams. To do.

  The cross dichroic prism 455 includes a light incident surface 4551 for entering each color light modulated for each color light emitted from the emission side polarizing plate 454, and synthesizes each color light incident on the light incident surface 4551 to produce a color image. Form. The cross dichroic prism 455 has a substantially square shape in plan view in which four right angle prisms are bonded together, and two dielectric multilayer films are formed at the interface where the right angle prisms are bonded together. These dielectric multilayer films transmit color light emitted from the light modulation device 451G and pass through the emission-side polarizing plate 454, and reflect each color light emitted from the light modulation devices 451R and 451B and passed through the emission-side polarizing plate 454. . In this way, the color lights are combined to form image light.

[Configuration of optical device]
FIG. 2 is a perspective view showing a part of the optical device 45. Specifically, the light modulation device 451R on the red light side is fixed to the cross dichroic prism 455.
FIG. 3 is an exploded perspective view of the optical device 45. Here, for convenience of explanation, the light emission side of the light modulation device 451R on the red light side is illustrated.
The optical device 45 includes a mounting member 4511 as shown in FIG. 2 or FIG. 3 in addition to the light modulation device 451, the incident side polarizing plate 452, the first polarizing plate 453, the emission side polarizing plate 454, and the cross dichroic prism 455 described above. , Holding member 4512, support member 4531, and translucent substrate 4541, and members 451, 453 to 455, 4511, 4512, 4531, and 4541 except for incident side polarizing plate 452 are integrated. It is.

As shown in FIG. 3, the attachment member 4511 has a substantially rectangular plate-like body and includes insertion holes 4511 </ b> A at four corners. As shown in FIG. 3, a light modulation device 451R is attached to the attachment member 4511 and holds the light modulation device 451R.
The insertion hole 4511A is a portion through which a protrusion 4512B of a holding member 4512 described later is inserted. Thereby, the attachment member 4511 and the holding member 4512 are integrated. By integrating these members 4511 and 4512, the light modulation device 451R is held. Then, the frame portion of the holding member 4512 comes into contact with the translucent substrate 4541 and the light modulation device 451R is fixed to the cross dichroic prism 455.

As shown in FIG. 3, the holding member 4512 has a frame-like body, and includes a rectangular opening 4512 </ b> A and projections 4512 </ b> B at four corners. Further, both end portions of the holding member 4512 are bent toward the light modulation device 451R side.
The opening 4512A is formed to have a size that allows the light beam to pass therethrough and allows the first polarizing plate 453, the emission-side polarizing plate 454, and the support member 4531 to be inserted therethrough.
The protrusion 4512B protrudes toward the light modulation device 451R and is inserted through the insertion hole 4511A.

FIG. 4 is a perspective view showing a state in which the first polarizing plate 453 and the exit-side polarizing plate 454 are attached to the light incident surface 4551 (see FIG. 1) of the cross dichroic prism 455, and the light modulation device 451 and the like are attached. It is a figure which shows the state which is not.
As shown in FIG. 3 or FIG. 4, the first polarizing plate 453 is formed in a rectangular shape, and is attached to the emission-side polarizing plate 454 via a support member 4531.
As shown in FIG. 3, the support member 4531 is formed in a frame-like body and has an opening 4531A. Further, as shown in FIGS. 3 and 4, the support member 4531 has a bent portion 4531 </ b> B that is formed in a U-shape by bending both end portions toward the light emission side of the first polarizing plate 453.
The opening 4531A is a part that allows the polarized light transmitted through the first polarizing plate 453 to pass therethrough.
A first polarizing plate 453 is attached to the bent portion 4531B to support the first polarizing plate 453. Accordingly, the first polarizing plate 453 is fixed to the support member 4531 in a state of being separated from the emission side polarizing plate 454.

As shown in FIG. 3, the emission-side polarizing plate 454 is attached to a light incident surface of a light-transmitting substrate 4541 having thermal conductivity.
The translucent substrate 4541 is made of a quartz plate, a sapphire plate, or the like. As shown in FIG. 3, the light-exiting surface of the translucent substrate 4541 is in direct contact with the light incident surface 4551 (see FIG. 1) of the cross dichroic prism 455, and the light incident-side surface The emission side polarizing plate 454 is attached and the holding member 4512 is brought into contact therewith.
Here, by providing the two polarizing plates 453 and 454, the incident polarized light is divided and absorbed by the first polarizing plate 453 and the exit-side polarizing plate 454, respectively. Then, the heat generated by the polarized light is apportioned by both polarizing plates 453 and 454 to suppress each overheating.

[Method for Manufacturing Optical Device]
The optical device 45 described above is manufactured as follows.
FIG. 5 is a flowchart showing a method for manufacturing the optical device 45.
First, a translucent member 4541 having an exit-side polarizing plate 454 is bonded to the light incident surface of the cross dichroic prism 455.
Then, a photocurable adhesive is applied to the bent portion 4531B of the support member 4531, and the light emission surface of the first polarizing plate 453 is brought into close contact with the bent portion 4531B of the support member 4531. Thereby, the 1st polarizing plate 453 and the supporting member 4531 are integrated (step S1).
Next, a photo-curing adhesive is applied to the light emission side frame portion of the support member 4531, and the first integrated with the light incident surface of the translucent substrate 4541 fixed to the cross dichroic prism 455. The polarizing plate 453 and the support member 4531 are brought into close contact with each other. At this time, using a jig (not shown), the external reference of the first polarizing plate 453 and the exit-side polarizing plate 454 is matched, and the light transmission axes of the first polarizing plate 453 and the exit-side polarizing plate 454 are aligned with each other. Position. Then, the photo-curing adhesive is cured by irradiating ultraviolet rays or the like, and is fixed in a state where the transmission axes of the light fluxes of the first polarizing plate 453 and the exit-side polarizing plate 454 coincide (step S2: optical element fixing step) ).
The process shown above results in the state shown in FIG.

Next, the light modulation device 451R is held by a jig (not shown) for adjusting the position of the light modulation device 451R, a photo-curing adhesive is applied to the four protrusions 4512B of the holding member 4512, and the protrusion 4512B. Is inserted through the insertion hole 4511A of the attachment member 4511 (step S3).
Next, a photocurable adhesive is applied to the surface of the frame portion on the light emission side of the holding member 4512 so that the holding member 4512 is brought into contact with the light incident surface 4551 of the cross dichroic prism 455. Specifically, the first polarizing plate 453, the support member 4531, and the emission-side polarizing plate 454 are inserted through the opening 4512A of the holding member 4512, and the holding member 4512 is brought into contact with the light-transmitting substrate 4541. In this case, alignment adjustment (X-axis direction and Y-axis direction orthogonal to the optical axis of the light beam incident on the light modulation device 451R, with the contact surface where the holding member 4512 and the translucent substrate 4541 are in contact as a sliding surface, (Adjustment with the rotation direction around the optical axis). In addition, the focus is adjusted by sliding through the joint surface of the attachment member 4511 and the holding member 4512, that is, the four protrusions 4512B (the direction along the optical axis, the rotation direction around the X axis, and (Adjustment with the rotation direction around the Y axis).
Then, after positioning the light modulation device 451R at a predetermined position, the light curable adhesive is cured by irradiating ultraviolet rays or the like, and the light modulation device 451 is attached to the translucent substrate 4541 through the holding member 4512. Fix (step S4: light modulation device fixing step).
Through the above steps, the optical device 45 shown in FIG. 2 is manufactured.

According to the projector 1 of the present embodiment described above, the following effects are obtained.
In this embodiment, first, the first polarizing plate 453 and the exit-side polarizing plate 454 are fixed to the light incident surface 4551 of the cross dichroic prism 455, and then the light modulation device 451 is fixed to the light incident surface 4551. To do. According to this, since the first polarizing plate 453 and the exit-side polarizing plate 454 are fixed to the light incident surface 4551 in advance, for example, position adjustment (alignment adjustment, focus adjustment) of the light modulation device 451 is performed thereafter. ), The first polarizing plate 453 and the exit-side polarizing plate 454 are fixed to each other and fixed to the cross dichroic prism 455, and therefore between the first polarizing plate 453 and the exit-side polarizing plate 454. In this case, the transmission axis does not deviate. Accordingly, it is possible to prevent a decrease in the contrast of the projected image due to the positional deviation between the first polarizing plate 453 and the exit side polarizing plate 454.

In addition, since the first polarizing plate 453 and the emission side polarizing plate 454 are supported by the support member 4531 in a state of being separated from each other, the first polarizing plate 453 and the emission side polarizing plate 454 can be supported with each other via the support member 4531.
That is, the first polarizing plate 453 and the emission side polarizing plate 454 can be supported in a state of being separated in advance via the support member 4531. The light modulation device 451 is supported by the protrusion 4512B of the holding member 4512 and the insertion hole 4511A of the attachment member 4511, and the holding member 4512 is fixed to the light incident surface of the translucent member 4541. For example, alignment adjustment is performed by using the light incident surface of the translucent member 4541 with which the holding member 4512 abuts as a sliding surface, and sliding is performed via the joint surface between the holding member 4512 and the mounting member 4511, that is, the protrusion 4512B. Adjust the focus.
Therefore, even when these adjustments of the light modulation device 451 are performed, it is possible to prevent a decrease in contrast of the projected image without causing a shift in the transmission axes of the first polarizing plate 453 and the emission-side polarizing plate 454.

[Modification of Embodiment]
It should be noted that the present invention is not limited to the above-described embodiments, and modifications, improvements, and the like within the scope that can achieve the object of the present invention are included in the present invention.
In the embodiment, two optical elements, the first polarizing plate 453 and the exit-side polarizing plate 454, are used. However, three or more optical elements may be used.
In the embodiment, the exit-side polarizing plate 454 is fixed to the cross dichroic prism 455 via the translucent substrate 4541. However, the translucent substrate 4541 may not be used. Alternatively, the first polarizing plate 453 may be attached to the light-transmitting substrate 4541 and then fixed to the support member 4531.
In the embodiment, the holding member 4512 is in contact with the translucent member 4541. However, the holding member 4512 may be in contact with a pedestal member that supports the cross dichroic prism 455 and other components. For example, the upper and lower end portions of the support member 4531 may be enlarged so that the holding member 4512 contacts.
In the embodiment, when the transmission axes of the light beams of the first polarizing plate 453 and the exit-side polarizing plate 454 are matched, the position is adjusted based on the outer shape reference. However, the position is adjusted while transmitting the light beam and observing the polarization state. May be.

In the above-described embodiment, the first polarizing plate 453 and the emission-side polarizing plate 454 are used as the optical elements, but other optical elements may be used.
In the embodiment, the optical unit 4 is configured to have a substantially L shape in plan view. However, the configuration is not limited thereto, and for example, a configuration having a substantially U shape in plan view may be employed.

  The present invention can be used for projectors used in presentations and home theaters.

  DESCRIPTION OF SYMBOLS 1 ... Projector, 45 ... Optical apparatus, 451 ... Light modulation apparatus, 453 ... 1st polarizing plate (other optical element), 454 ... Ejection side polarizing plate (1st optical element), 455 ... Cross dichroic prism (color synthesis) Optical device), 4512 ... Holding member (second support member), 4531 ... Support member (first support member), 4551 ... Light incident surface, S2 ... Optical element fixing step, S4 ... Light modulation device fixing step.

Claims (2)

Combining a plurality of light modulation devices that modulate a plurality of color lights according to image information for each color light, and a plurality of light incident surfaces facing each of the light modulation devices, and each color light modulated by each of the light modulation devices A color synthesizing optical device that forms an image, and a method of manufacturing an optical device comprising the light modulation device and a plurality of optical elements disposed between the light incident surfaces,
An optical element fixing step of fixing the plurality of optical elements to the light incident surface;
An optical device manufacturing method comprising: a light modulation device fixing step of fixing the light modulation device to the light incident surface after the optical element fixing step. Combining a plurality of light modulation devices that modulate a plurality of color lights according to image information for each color light, and a plurality of light incident surfaces facing each of the light modulation devices, and each color light modulated by each of the light modulation devices A color synthesizing optical device that forms an image, and a plurality of optical elements disposed between the light modulation device and the light incident surface,
A first optical element fixed to the light incident surface among the plurality of optical elements;
Another optical element disposed on the light incident side of the first optical element;
A first support member for supporting the other optical element in a state of being separated from the first optical element, and supporting the other optical element in a state of being separated from each other;
A projector comprising: a second support member fixed to the light incident surface and supporting the light modulation device.

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