JP5741916B2 - Light source device manufacturing method, light source device, and projector - Google Patents

Description

  The present invention relates to a light source device manufacturing method, a light source device, and a projector.

  2. Description of the Related Art Today, data projectors are widely used as image projection apparatuses that project a screen of a personal computer, a video image, an image based on image data stored in a memory card or the like onto a screen. This projector focuses light emitted from a light source on a micromirror display element called DMD (digital micromirror device) or a liquid crystal plate, and displays a color image on a screen.

  With the spread of video equipment such as personal computers and DVD players, the use of projectors has expanded from business presentations to home use. In such projectors, a projector using a high-intensity discharge lamp as a light source has been mainly used in the past. However, in recent years, a semiconductor light emitting device such as a plurality of laser diodes is used as a light source, and a plurality of lenses, mirrors, etc. There have been many developments and proposals of light source devices composed of optical components.

  And in JP, 2011-13317, A (patent documents 1) which the present applicant applied for earlier, in the composition which arranged a plurality of light sources in the shape of a matrix, the interval of the emitted light from each light source was arranged in the step shape. A projector having a light source device capable of reducing the cross-sectional area of a light beam emitted from a plurality of bright spots by narrowing it with a mirror is proposed.

JP 2011-13317 A

  However, in the projector described above, the interval between the light emitted from each light source can be reduced by a plurality of mirrors, but after being molded by injection molding using a die such as an aluminum die cast, it is commercialized by machining. In some cases, the mirror holder cannot be accurate due to warpage or surface variations. In this case, even if it is attempted to improve accuracy by adjustment or the like, it is difficult to adjust all the tilt and position adjustments of the plurality of mirrors to the standard.

  The present invention has been made in view of the above-described problems of the prior art, and a method for manufacturing a light source device and a method for manufacturing the same capable of arranging a number of mirrors with their inclinations accurately matched. It is an object of the present invention to provide a light source device manufactured by the above and a projector including the light source device.

The method for manufacturing a light source device according to the present invention is a method for manufacturing a light source device in which a group of mirrors each having a plurality of mirrors is installed at a predetermined angle, and has a mounting surface on which the plurality of mirrors are mounted at a predetermined angle. And a preparation step of preparing a jig having suction means for sucking and fixing the large number of mirrors, and a suction step of mounting the large number of mirrors at a predetermined position of the jig and sucking and fixing by the suction means; An adhering step of adhering and fixing each of the mirrors between adjacent mirror edge portions and a mirror back surface in a state in which the plurality of mirrors are adsorbed by the adsorbing means of the jig; A mounting step of mounting a group of mirrors connected to each other on a flat mirror substrate, and filling the gap between the mirror group and the flat mirror substrate with a filler. A group and the mirror substrate A fixing step of integrally bonded and fixed, the mirror substrate, and the mirror mounting step of mounting the reflection mirror group holder of the light source holder for holding the light source group,
It is characterized by including.

The light source device of the present invention includes a light source group in which a plurality of light sources are arranged in a plane so as to form rows and columns, and parallel light so as to enhance the directivity of each emitted light from each light source of the light source group. A collimator lens to be converted, a mirror group composed of a plurality of mirrors that reduce the area of the bundle of light beams of each of the emitted light beams that have passed through the collimator lens and reflect the light beams so as to be emitted at a predetermined angle; And a mirror substrate for supporting the back surface of the mirror group connected by the adhesive portion via a filler, and the mirror group And a condensing lens for condensing the light flux reflected by.

  The projector of the present invention includes a light source device, a display element, a light source side optical system that guides light from the light source device to the display element, and a projection side optical that projects an image emitted from the display element onto a screen. A light source device that emits red wavelength band light, a light source device that emits blue wavelength band light, and green wavelength band light. A light source device that emits light, wherein at least one of the light source devices is the above-described light source device of the present invention.

  According to the present invention, a manufacturing method of a light source device capable of arranging a large number of mirrors in a state in which the inclinations thereof are accurately matched, a light source device manufactured by the manufacturing method, and a projector including the light source device are provided. Can be provided.

1 is an external perspective view showing a projector according to an embodiment of the invention. It is a figure which shows the functional block of the projector which concerns on embodiment of this invention. 1 is a schematic plan view showing an internal structure of a projector according to an embodiment of the invention. It is explanatory drawing which shows the structure of the light source device which concerns on embodiment of this invention. It is explanatory drawing regarding the method of adhere | attaching the reflective mirror which concerns on embodiment of this invention on a jig | tool. It is a figure which shows the state which fixed the reflective mirror group and mirror substrate which concern on embodiment of this invention. It is a flowchart regarding the method to adhere | attach the reflective mirror which concerns on embodiment of this invention on a jig | tool.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is an external perspective view of the projector 10. In the present embodiment, left and right in the projector 10 indicate the left and right direction with respect to the projection direction, and front and rear indicate the screen side direction of the projector 10 and the front and rear direction with respect to the traveling direction of the light beam.

  As shown in FIG. 1, the projector 10 has a substantially rectangular parallelepiped shape, and has a lens cover 19 that covers the projection port on the side of the front panel 12 that is a front side plate of the projector housing. The panel 12 is provided with a plurality of intake holes 18. Further, although not shown, an IR receiver for receiving a control signal from the remote controller is provided.

  In addition, a key / indicator unit 37 is provided on the top panel 11 of the housing. The key / indicator unit 37 switches a power switch key, a power indicator for notifying power on / off, and switching on / off of projection. Keys and indicators such as an overheat indicator for notifying when a projection switch key, a light source unit, a display element, a control circuit, etc. are overheated are arranged.

  In addition, an input / output connector portion provided with a D-SUB terminal, an S terminal, an RCA terminal, an audio output terminal, and the like for inputting a video signal to which a USB terminal or an analog RGB video signal is input to the rear panel is provided on the rear surface of the housing; Various terminals 20 such as a power adapter plug are provided. In addition, a plurality of intake holes are formed in the back panel. A plurality of exhaust holes 17 are formed in each of the right panel, which is a side plate of the housing (not shown), and the left panel 15, which is the side plate shown in FIG. An intake hole 18 is also formed at a corner near the back panel of the left panel 15.

  Next, projector control means of the projector 10 will be described with reference to the functional block diagram of FIG. The projector control means includes a control unit 38, an input / output interface 22, an image conversion unit 23, a display encoder 24, a display drive unit 26, and the like.

  The control unit 38 controls the operation of each circuit in the projector 10, and includes a CPU, a ROM that stores operation programs such as various settings fixedly, and a RAM that is used as a work memory. Yes.

  Then, the image signal of various standards input from the input / output connector unit 21 by the projector control means is in a predetermined format suitable for display by the image conversion unit 23 via the input / output interface 22 and the system bus (SB). After being converted so as to be unified into an image signal, it is output to the display encoder 24.

  The display encoder 24 develops and stores the input image signal in the video RAM 25, generates a video signal from the stored contents of the video RAM 25, and outputs the video signal to the display drive unit 26.

  The display drive unit 26 functions as display element control means, and drives the display element 51, which is a spatial light modulation element (SOM), at an appropriate frame rate corresponding to the image signal output from the display encoder 24. By irradiating the display element 51 with a light bundle emitted from the light source unit 60 via a light source side optical system, which will be described later, an optical image is formed with the reflected light of the display element 51, and the projection side optical system is The image is projected and displayed on a screen (not shown). The movable lens group 235 of the projection side optical system is driven by the lens motor 45 for zoom adjustment and focus adjustment.

  Further, the image compression / decompression unit 31 performs a recording process in which the luminance signal and the color difference signal of the image signal are data-compressed by a process such as ADCT and Huffman coding, and are sequentially written in a memory card 32 which is a detachable recording medium. .

  Further, the image compression / decompression unit 31 reads out the image data recorded on the memory card 32 in the reproduction mode, decompresses individual image data constituting a series of moving images in units of one frame, and converts the image data into the image conversion unit. A process for enabling display of a moving image or the like based on the image data output to the display encoder 24 and stored in the memory card 32 is performed.

  Then, the operation signal of the key / indicator unit 37 composed of the main key and the indicator provided on the top panel 11 of the casing is directly sent to the control unit 38, and the key operation signal from the remote controller is received by IR. The code signal received by the unit 35 and demodulated by the IR processing unit 36 is output to the control unit 38.

  Note that an audio processing unit 47 is connected to the control unit 38 via a system bus (SB). The sound processing unit 47 includes a sound source circuit such as a PCM sound source, converts the sound data into analog in the projection mode and the playback mode, and drives the speaker 48 to emit loud sounds.

  Further, the control unit 38 controls a light source control circuit 41 as a light source control means, and the light source control circuit 41 is configured so that light of a predetermined wavelength band required at the time of image generation is emitted from the light source unit 60. Individual control for emitting light in the red, green and blue wavelength bands of the light source unit 60 is performed.

  Further, the control unit 38 causes the cooling fan drive control circuit 43 to perform temperature detection using a plurality of temperature sensors provided in the light source unit 60 and the like, and controls the rotation speed of the cooling fan from the result of the temperature detection. Further, the control unit 38 causes the cooling fan drive control circuit 43 to keep the cooling fan rotating even after the projector body is turned off by a timer or the like, or to turn off the projector body depending on the result of temperature detection by the temperature sensor. Control is also performed.

  Next, the internal structure of the projector 10 will be described. FIG. 3 is a schematic plan view showing the internal structure of the projector 10. FIG. 4 is an explanatory diagram of the light source device in the projector 10. As shown in FIG. 3, the projector 10 includes a control circuit board 241 in the vicinity of the right panel 14. The control circuit board 241 includes a power circuit block, a light source control block, and the like. In addition, the projector 10 includes a light source unit 60 on the side of the control circuit board 241, that is, at a substantially central portion of the projector housing. Further, the projector 10 includes an optical system unit 160 between the light source unit 60 and the left panel 15.

  The light source unit 60 includes a blue light source device 70 disposed in the vicinity of the rear panel 13 at a substantially central portion in the left-right direction of the projector housing, and an optical axis of a light beam emitted from the blue light source device 70. A fluorescent light emitting device 100 disposed in the vicinity of the front panel 12, a red light source device 120 disposed between the blue light source device 70 and the fluorescent light emitting device 100, light emitted from the fluorescent light emitting device 100, and a red light source device 120 A light guide optical system 140 that converts the optical axis of the emitted light from the light beam to the same optical axis and collects each color light at the entrance of the light tunnel 175 that is a predetermined surface.

  The blue light source device 70 is a light source group composed of a plurality of blue light sources 71 arranged so that the optical axis is parallel to the rear panel 13, and converts the optical axis of the emitted light from each blue light source 71 by 90 degrees in the direction of the front panel 12. A reflecting mirror group 75, a condenser lens 78 for condensing the emitted light from each blue light source 71 reflected by the reflecting mirror group 75, and a heat sink 81 arranged between the blue light source 71 and the right panel 14. Prepare.

  The light source group is configured by arranging a plurality of blue light sources 71 as blue laser emitters in a matrix. On the optical axis of each blue light source 71, a collimator lens 73 that converts each of the emitted light from each blue light source 71 into parallel light is arranged so as to enhance the directivity of each emitted light. In addition, the reflecting mirror group 75 is formed by aligning a plurality of reflecting mirrors in a stepped manner and integrated with the mirror substrate 76 to adjust the position, and the cross-sectional area of the light beam emitted from the blue light source 71 is set in one direction. And is emitted to the condenser lens 78. The reflecting mirror group 75 will be described in detail later.

  A cooling fan 261 is disposed between the heat sink 81 and the back panel 13, and the blue light source 71 is cooled by the cooling fan 261 and the heat sink 81. Further, a cooling fan 261 is also disposed between the reflection mirror group 75 and the back panel 13, and the reflection mirror group 75 and the condenser lens 78 are cooled by the cooling fan 261.

  The fluorescent light emitting device 100 is arranged to be parallel to the front panel 12, that is, the light emitting wheel 101 disposed so as to be orthogonal to the optical axis of the light emitted from the blue light source device 70, and the light emitting wheel 101 is rotationally driven. A wheel motor 110, a light collecting lens group 111 for condensing the light bundle emitted from the blue light source device 70 onto the light emitting wheel 101 and the light bundle emitted from the light emitting wheel 101 toward the rear panel 13, and light emission And a condensing lens 115 that condenses the light bundle emitted from the wheel 101 toward the front panel 12.

  The light emitting wheel 101 receives the emitted light from the blue light source device 70 as excitation light and emits the green fluorescent light emitting region as the green light source device 80 that emits the fluorescent light emitted in the green wavelength band, and the emitted light from the blue light source device 70. A diffusion transmission region that diffuses and transmits is juxtaposed in the circumferential direction. Further, the base material in the green fluorescent light emitting region is a metal base material made of copper, aluminum or the like, and the surface of the base material on the back panel 13 side is mirror processed by silver vapor deposition or the like. A green phosphor layer is laid on the surface. Furthermore, the base material in the diffuse transmission region is a transparent base material having translucency, and fine irregularities are formed on the surface of the base material by sandblasting or the like.

  The emitted light from the blue light source device 70 irradiated on the green phosphor layer as the green light source device of the light emitting wheel 101 excites the green phosphor in the green phosphor layer and emits fluorescence from the green phosphor in all directions. The light beam thus emitted is directly emitted to the rear panel 13 side or reflected by the surface of the light emitting wheel 101 and then emitted to the rear panel 13 side and enters the condenser lens group 111. Further, the light emitted from the blue light source device 70 irradiated on the diffuse transmission region of the light emitting wheel 101 is incident on the condenser lens 115 as diffuse transmission light diffused by the fine unevenness. A cooling fan 261 is disposed between the wheel motor 110 and the front panel 12, and the fluorescent light emitting device 100 and the like are cooled by the cooling fan 261.

  The red light source device 120 is a monochromatic light emitting device including a red light source 121 arranged so that the optical axis is parallel to the blue light source 71, and a condensing lens group 125 that collects light emitted from the red light source 121. is there. The red light source 121 is a red light emitting diode that emits light in the red wavelength band. The red light source device 120 is arranged so that the light beams emitted from the blue light source device 70 and the green wavelength band light emitted from the light emitting wheel 101 intersect the optical axis. Furthermore, the red light source device 120 includes a heat sink 130 disposed on the right panel 14 side of the red light source 121. A cooling fan 261 is disposed between the heat sink 130 and the front panel 12, and the red light source 121 is cooled by the cooling fan 261.

  The light guide optical system 140 includes a condensing lens that condenses the light bundles in the red, green, and blue wavelength bands, and a reflection mirror that converts the optical axes of the light bundles in the respective color wavelength bands into the same optical axis, It consists of a dichroic mirror. Specifically, at the position where the blue wavelength band light emitted from the blue light source device 70 and the green wavelength band light emitted from the light emitting wheel 101 intersect the red wavelength band light emitted from the red light source device 120, A first dichroic mirror 141 that transmits blue and red wavelength band light, reflects green wavelength band light, and converts the optical axis of the green light by 90 degrees toward the left panel 15 is disposed.

  Also, on the optical axis of the blue wavelength band light diffusely transmitted through the light emitting wheel 101, that is, between the condenser lens 115 and the front panel 12, the blue wavelength band light is reflected and the optical axis of the blue light is on the left side. A first reflecting mirror 143 that converts 90 degrees in the direction of the panel 15 is disposed. Further, on the optical axis of the blue wavelength band light reflected by the first reflection mirror 143 and in the vicinity of the optical system unit 160, a second reflection mirror for converting the optical axis of the blue light by 90 degrees in the direction of the back panel 13 145 is arranged.

  Further, the optical axis of the red wavelength band light transmitted through the first dichroic mirror 141, the optical axis of the green wavelength band light reflected by the first dichroic mirror 141 so as to coincide with this optical axis, and the second reflection mirror 145 At the position where the optical axis of the reflected blue wavelength band light intersects, the blue wavelength band light is transmitted, the red and green wavelength band light is reflected, and the optical axes of the red and green light are 90 degrees toward the rear panel 13. A second dichroic mirror 148 for changing the degree is arranged. A condensing lens is disposed between the dichroic mirror and the reflecting mirror. Further, in the vicinity of the light tunnel 175, a condenser lens 173 that condenses the light source light at the entrance of the light tunnel 175 is disposed.

  The optical system unit 160 includes an illumination side block 161 located on the left side of the blue light source device 70, an image generation block 165 located near the position where the back panel 13 and the left panel 15 intersect, and the light guide optical system 140. And the projection side block 168 located between the left side panel 15 and the left side panel 15 are formed in a substantially U-shape.

  The illumination side block 161 includes a part of the light source side optical system 170 that guides the light source light emitted from the light source unit 60 to the display element 51 provided in the image generation block 165. As the light source side optical system 170 included in the illumination side block 161, the light tunnel 175 that uses the light beam emitted from the light source unit 60 as a light flux having a uniform intensity distribution and the light emitted from the light tunnel 175 are condensed. There are a condensing lens 178, an optical axis conversion mirror 181 that converts the optical axis of the light beam emitted from the light tunnel 175 in the direction of the image generation block 165, and the like.

  As the light source side optical system 170, the image generation block 165 includes a condenser lens 183 that condenses the light source light reflected by the optical axis conversion mirror 181 on the display element 51, and a light beam that has passed through the condenser lens 183 as a display element. And an irradiation mirror 185 that irradiates 51 at a predetermined angle. Further, the image generation block 165 includes a DMD serving as the display element 51, and a heat sink 190 for cooling the display element 51 is disposed between the display element 51 and the rear panel 13. Element 51 is cooled. Further, a condenser lens 195 as the projection-side optical system 220 is disposed near the front surface of the display element 51.

  The projection-side block 168 has a lens group of the projection-side optical system 220 that emits ON light reflected by the display element 51 to the screen. The projection-side optical system 220 includes a fixed lens group 225 built in a fixed lens barrel and a movable lens group 235 built in a movable lens barrel, and is a variable focus lens having a zoom function, and is movable by a lens motor. Zoom adjustment and focus adjustment can be performed by moving the lens group 235.

  By configuring the projector 10 in this manner, when the light emitting wheel 101 is rotated and light is emitted from the blue light source device 70 and the red light source device 120 at different timings, red, green, and blue wavelength band lights are guided by the light guide optical system. Since the light is sequentially incident on the light tunnel 175 via 140 and further incident on the display element 51 via the light source side optical system 170, the DMD which is the display element 51 of the projector 10 time-divides each color light according to the data. By displaying, a color image can be generated on the screen.

  Next, the configuration of the light source device of the present invention will be described in detail with reference to the drawings. FIG. 4 is an explanatory diagram showing a configuration around the reflection mirror group 75 of the blue light source device 70.

  As described above, the blue light source device 70 includes a blue light source 71 that is a light source group of a plurality of semiconductor light emitting elements, a collimator lens 73 that converts each of the emitted light from the blue light source 71 into parallel light, and a blue light source 71 A reflection mirror group 75 composed of a plurality of reflection mirrors 75a that converts the optical axis of the emitted light by 90 degrees and a condenser lens 78 that condenses the emitted light from the blue light source 71 reflected by the reflection mirror group 75 are provided.

  As shown in FIG. 4, the reflection mirror group 75 is arranged in parallel so that a plurality of reflection mirrors are stepped, and is integrated with the mirror substrate 76.

  The reflecting mirror group 75 is formed with an adhesive portion 77 by fixing the edges of the reflecting mirrors 75a and the back surface of the adjacent reflecting mirror 75a with, for example, a UV curable (ultraviolet curable) adhesive or the like. Each reflecting mirror 75a is integrated.

  Further, with each reflection mirror 75a being integrated, a mirror substrate 76 is engaged with the back surface of each reflection mirror 75a of the reflection mirror group 75, and, for example, UV curing is performed between the reflection mirror group 75 and the mirror substrate 76. The reflecting mirror group 75 and the mirror substrate 76 are integrated by injecting and fixing a filler 74 made of a mold adhesive or the like.

  The mirror substrate 76 is a flat and substantially rectangular metal base material, and includes locking portions that are locked to the reflecting mirror group holding body 72 at both ends.

  The locking part has a hole 404 (hole) for locking one end of both ends to a protrusion 500 provided on one of both ends of the reflecting mirror group holding body 72 as a light source holding body, and the other of the both ends. A long hole 405 serving as a position adjusting unit 403 corresponding to a screw hole 501 (screw hole portion) provided on the other end of both ends of the reflection mirror group holding body 72 is used. Therefore, the position adjusting means 403 is inserted in the state where the screw 406 is passed through the position adjusting means 403 which is the other end of the mirror substrate 76 and the other end of the mirror substrate 76 and the screw hole 501 of the reflecting mirror group holding body 72. The position of the mirror substrate 76 is adjusted by moving the mirror substrate 76 to adjust the mounting position of the mirror substrate 76 so that a predetermined mounting angle is obtained. The mirror substrate 76 and the reflecting mirror group holding body 72 are connected by stopping the elongated hole 405 and the screw hole 501 of the reflecting mirror group holding body 72 with the screw 406.

  Since the mirror substrate 76 includes the locking portion including the position adjusting means 403 as described above, the attachment angle of the mirror substrate 76 to the reflection mirror group holding body 72 can be easily adjusted.

  Further, as described above, the blue light source 71 is configured by arranging blue laser diodes, which are a total of 24 semiconductor light emitting elements in 3 rows and 8 columns, in a matrix.

  The reflecting mirror group 75 is composed of eight strip-shaped reflecting mirrors 75a that are the same as the number of light sources in the blue light source 71, and the reflecting mirrors 75a are arranged with the same inclination. ing.

  The reflecting mirror group 75 is not limited to the case where the reflecting mirror group 75 is configured by eight strip-shaped mirrors that are the same as the number of light sources in the blue light source 71. The reflection mirror 75a is composed of 24 reflection mirrors 75a, and the reflection mirrors 75a are arranged with the same inclination, so that the reflection mirrors 75a reduce the interval between the reflected lights from the reflection mirrors 75a. It may be arranged.

  Next, a manufacturing method for manufacturing the light source device using the jig 400 or the like will be described with reference to the drawings. FIG. 5 is an explanatory diagram relating to a method of bonding the reflection mirror 75a on the jig 400. FIG. FIG. 6 is an explanatory diagram showing a state in which the reflection mirror group 75 formed by integrating the reflection mirror 75a and the mirror substrate 76 are fixed. FIG. 7 is a flowchart of a manufacturing method for manufacturing the light source device using the jig 400 or the like.

  The light source device is manufactured using the jig 400, the suction means 401, and the like in order to arrange the reflecting mirrors 75a in parallel with the same inclination so as to form an integrated structure as the reflecting mirror group 75.

  First, a preparation step (step S600) for preparing the jig 400 at a predetermined place is performed. As shown in FIG. 5, the jig 400 is a mounting table having reflection mirror arrangement surfaces for arranging the reflection mirrors 75a parallel to each other in a stepwise manner at an angle of 45 degrees with respect to the horizontal plane.

  In addition, the jig 400 is formed with an intake hole formed to open on each reflection mirror arrangement surface. Then, an adsorption step (in which each reflection mirror 75a placed on each reflection mirror arrangement surface of the jig 400 is adsorbed on each reflection mirror arrangement surface by being sucked by an unillustrated vacuum device or the like through an intake hole as an adsorption means 401 ( Step S601) is performed.

  Then, in a state where each reflecting mirror 75a is placed on each reflecting mirror arrangement surface and is attracted by the attracting means 401, the reflecting mirror 75a is adjacent to the reflecting mirror edge on the surface opposite to the attracting surface of each reflecting mirror 75a. An adhesion step (step S602) is performed in which the back surface is fixed with, for example, a UV curable adhesive or the like to form the adhesion portion 77.

  Next, as shown in FIG. 6, a mounting step (step S603) is performed in which the reflecting mirror group 75 connected and integrated with each other by the bonding portion 77 is mounted on the flat mirror substrate 76. Then, a fixing step (step S604) is performed in which the reflective mirror group 75 and the mirror substrate 76 are integrated by injecting the filler 74 into the gap between the reflective mirror group 75 and the mirror substrate 76.

  Thereafter, the mirror substrate 76 is attached to the reflection mirror group holding body 72, which is a light source holding body that holds the reflection mirror group 75 integrated with the mirror substrate 76, by the position adjusting means 403 that is a long hole 405 at the end of the mirror substrate 76. An attaching mirror attaching step (step S605) is performed.

  In attaching the mirror substrate 76 to the reflecting mirror group holder 72, for example, with the blue light source 71 turned on using a lighting jig or the like, the end of the mirror substrate 76 is moved as described above. After adjusting whether or not the emitted light is perpendicular to the condenser lens 78 and completing the vertical adjustment, the elongated hole 405 provided with the mirror substrate 76 and the reflection mirror group holding body 72 at the end of the mirror substrate 76. The screw hole 501 may be fixed by closing the screw 406.

  Specifically, as a mirror mounting step (step S605), a step of locking the projection 404 of the reflecting mirror group holding body 72 in the hole 404 of the mirror substrate 76, and a position adjusting means 403 by the long hole 405 of the mirror substrate 76. And the step of passing the screw 406 through the screw hole 501 of the reflecting mirror group holding body 72, the step of moving the mirror substrate 76 so as to rotate the position adjusting means 403, and the position adjustment of the mirror substrate 76, and the screw 406 The step of fixing the mirror substrate 76 and the reflecting mirror group holding body 72 by closing is performed.

  By manufacturing through these steps, the attachment angle of the mirror substrate 76 to the reflection mirror group holding body 72 can be easily finely adjusted by the position adjusting means 403.

  In this way, each reflecting mirror 75a is integrated with the mirror substrate 76 in a state where it is inclined 45 degrees with respect to the optical axis of the emitted light in order to change the direction of the emitted light from the blue light source 71 by 90 degrees. Thus, there is no need to individually adjust the angle of the reflecting mirror 75a provided for each row of the blue light sources 71, and the angle of the reflecting mirror group 75 can be adjusted only by adjusting the mounting position of the integrated reflecting mirror group 75. Can be completed.

  In the above embodiment, the configuration of the blue light source device 70 has been described as the light source device of the projector 10. However, the light source device of the present invention includes, for example, a plurality of light sources for the red light source device and the green light source device of the projector 10. And a light source group arranged in a plane so as to form a row, and a mirror group composed of a plurality of mirrors that reflect each light bundle emitted from each light source so as to be emitted at a predetermined angle. The same applies to the configuration.

  As described above, according to the embodiment of the present invention, a manufacturing method of a light source device capable of arranging a large number of mirrors with their inclinations accurately matched, a light source device manufactured by the manufacturing method, and its The projector 10 provided with the light source device can be provided.

  In addition, according to the embodiment of the present invention, by using an appropriate jig 400 having a reflection mirror arrangement surface with high flatness, it is possible to arrange a large number of reflection mirrors 75a with high accuracy and integrate them, Since the optical system can be adjusted with an easy adjustment mechanism, the productivity can be improved and the power of the laser light source can be maximized, so that the performance of the projection luminance can be improved.

  According to the embodiment of the present invention, the mirror substrate 76 has a flat plate shape, and it is difficult for warp or the like to occur by increasing the flatness.

  Furthermore, according to the embodiment of the present invention, the reflecting mirror group 75 includes a plurality of reflecting mirrors 75a arranged in parallel at a predetermined angle on the optical axis of the light beam emitted from the blue light source 71. The emission area of the light bundle can be reduced, and the light source device can be made compact.

  According to the embodiment of the present invention, the number of parts and the number of manufacturing steps can be reduced by forming the reflecting mirror group 75 as a strip-like reflecting mirror 75a having the same number as the number of light sources in the blue light source 71. .

  Further, according to the embodiment of the present invention, if the reflecting mirror group 75 is the same number of reflecting mirrors 75a as the number of light sources in the blue light source 71, the mirror is finely adjusted for each light source by adjusting the jig 400. can do.

  In addition, according to the embodiment of the present invention, it is not necessary to individually adjust the angle of the reflection mirror 75a provided for each row of the blue light sources 71, and only by adjusting the mounting position of the reflection mirror group 75 integrated, The angle adjustment of the reflection mirror group 75 can be completed.

  Then, according to the embodiment of the present invention, each reflecting mirror 75a is placed on a predetermined surface, and each reflecting mirror 75a is fixed with an adhesive or the like while adsorbing each reflecting mirror 75a with the suction means 401, and each reflecting mirror 75a is fixed. By integrating the mirror 75a and the mirror substrate 76, it is possible to easily adjust the mounting position of the mirror substrate 76 integrated with each reflecting mirror 75a, and to improve the performance of the projection luminance.

  In the present embodiment, it is preferable that the adhesive portion 77 and the filler 74 are not adhesives that are weakened by heat or have elasticity such as rubber after curing. For example, other than UV curable adhesives In addition, a thermosetting adhesive may be used.

  In addition, the jig 400 according to the present embodiment may be provided with a measure for preventing the adhesive from remaining. In a state where the adhesive remains on the jig 400 and is hardened, and the adhesive remains on the jig 400, it may be difficult to place the reflecting mirrors 75a with high accuracy even if they are attracted. Therefore, silicon rubber may be embedded in an end portion that is considered to come into contact with the adhesive of the jig 400, or the surface of the jig 400 may be coated with Teflon (registered trademark) to make it difficult to attach the adhesive.

  Although several embodiments of the present invention have been described, these embodiments are presented by way of example and are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention. These embodiments and modifications thereof are included in the scope and gist of the invention, and are included in the invention described in the claims and the equivalents thereof.

The invention described in the first claim of the present application will be appended below.
[1] A method of manufacturing a light source device in which a group of mirrors each having a plurality of mirrors is installed at a predetermined angle,
A preparation step of preparing a jig having a mounting surface for mounting the multiple mirrors at a predetermined angle and having a suction means for sucking and fixing the multiple mirrors;
An adsorption step in which the plurality of mirrors are placed at predetermined positions of the jig and are adsorbed and fixed by the adsorption means;
An adhesion step of forming an adhesion portion by adhering and fixing each of the mirrors between adjacent mirror edges and a mirror back surface in a state where the many mirrors are adsorbed by the adsorption means of the jig;
A mounting step of mounting a group of mirrors connected and integrated with each other by the bonding portion on a flat mirror substrate;
A fixing step of injecting a filler into a gap between the mirror group and the flat mirror substrate to bond and fix the mirror group and the mirror substrate together;
A mirror mounting step of attaching the mirror substrate to a reflection mirror group holding body of a light source holding body holding a light source group;
The manufacturing method of the light source device characterized by the above-mentioned.
[2] A hole is provided in one of the both ends of the mirror substrate, and a long hole is provided as a position adjusting means on the other.
One of the both ends of the light source holder is provided with a protrusion, and the other is provided with a screw hole.
The mirror mounting process includes
Locking the hole to the protrusion; and
Next, passing a screw through the position adjusting means and the screw hole;
Next, the step of adjusting the position of the mirror substrate by moving the mirror substrate so as to rotate the position adjustment means,
The method for manufacturing a light source device according to claim 1, further comprising: fixing the mirror substrate and the light source holder by closing the screw.
[3] The light source according to claim 1 or 2, wherein the mirror group includes a plurality of mirrors arranged stepwise and in parallel on an optical axis of a light beam emitted from the light source group. Device manufacturing method.
4. The mirror group is a strip-like mirror having the same number as the number of light sources in the light source group, and each mirror is disposed with the same inclination. The manufacturing method of the light source device in any one of Claim 3.
5. The mirror group is composed of the same number of mirrors as the number of light sources in the light source group, and each mirror is arranged with the same inclination. 5. A method for manufacturing a light source device according to any one of 4 above.
[6] The method for manufacturing a light source device according to any one of [1] to [5], wherein the adhesive portion and the filler are an ultraviolet curable resin adhesive or a thermosetting resin adhesive.
[7] A light source group in which a plurality of light sources are arranged in a plane so as to form rows and columns;
A collimator lens that converts each emitted light from each light source into parallel light, and
A mirror group consisting of a plurality of mirrors that reflect each light bundle emitted from each light source so as to be emitted at a predetermined angle;
An adhesive portion for connecting the edge portions of the plurality of mirrors and a back surface of an adjacent mirror to unite the mirror group;
A mirror substrate that supports a back surface of the mirror group connected by the adhesive portion via a filler;
A condensing lens that condenses the light emitted from the light source group;
A light source device comprising:
[8] The light source device further includes a mirror group holding body for holding the mirror group,
Both ends of the mirror substrate are provided with holes for locking the mirror group holding body on the one hand, and position adjustment for locking the mirror group holding body on the other side while making it possible to adjust the mounting position of the mirror group holding body. The light source device according to claim 7, further comprising a long hole as a means.
[9] a light source device;
A display element;
A light source side optical system for guiding light from the light source device to the display element;
A projection-side optical system that projects an image emitted from the display element onto a screen;
Projector control means for controlling the light source device and the display element,
The light source device is a light source device that emits red wavelength band light, a light source device that emits blue wavelength band light, or a light source device that emits green wavelength band light, and at least one of the light source devices is claim 7 or claim. Item 9. A light source device according to Item 8, wherein the projector is a light source device.

10 Projector 11 Top panel
12 Front panel
13 Rear panel 14 Right panel
15 Left panel 17 Exhaust hole
18 Air intake hole 19 Lens cover
20 Various terminals 21 Input / output connector
22 I / O interface 23 Image converter
24 Display encoder 25 Video RAM
26 Display drive unit 31 Image compression / decompression unit
32 Memory card 35 IR receiver
36 IR processing section 37 Key / indicator section
38 Control unit 41 Light source control circuit
43 Cooling fan drive control circuit 45 Lens motor
47 Audio processor 48 Speaker
51 Display element 60 Light source unit
70 Blue light source device 71 Blue light source
72 Reflective mirror group holder
73 Collimator lens 74 Filler
75 Reflective mirror group 75a Reflective mirror
76 Mirror substrate 77 Bonded part
78 Condenser lens 80 Green light source device
81 heat sink
100 Fluorescent light emitting device 101 Light emitting wheel
110 wheel motor
111 Condensing lens group
120 Red light source 121 Red light source
125 condenser lens group 130 heat sink
140 Light guide optical system 141 First dichroic mirror
143 First reflection mirror 145 Second reflection mirror
148 Second dichroic mirror
160 Optical unit 161 Illumination side block
165 Image generation block 168 Projection side block
170 Light source side optical system 173 Condensing lens
175 Light Tunnel
178 condenser lens
181 Optical axis conversion mirror 183 Condensing lens
185 Irradiation mirror 190 Heat sink
195 Condenser lens 220 Projection-side optical system
225 Fixed lens group 235 Movable lens group
241 Control circuit board 261 Cooling fan
400 Jig 401 Adsorption means
403 Position adjustment means
404 hole 405 oblong hole
406 Screw
500 Projection 501 Screw hole

Claims (9)

A method of manufacturing a light source device in which a group of mirrors each having a plurality of mirrors is installed at a predetermined angle, and includes a mounting surface on which the plurality of mirrors are mounted at a predetermined angle, and the plurality of mirrors are fixed by suction. A preparatory step of preparing a jig having a suction means to perform, a suction step of placing the plurality of mirrors at a predetermined position of the jig and suction fixing by the suction means, and a plurality of mirrors of the jig An adhering step of adhering and fixing the mirrors between adjacent mirror edges and the back of the mirror in a state of being adsorbed by the adsorbing means; and an integrated mirror connected to each other by the adhering part Placing the group on a flat mirror substrate, and injecting a filler into a gap between the mirror group and the flat mirror substrate to bond and fix the mirror group and the mirror substrate Unity And a mirror mounting step for attaching the mirror substrate to a reflection mirror group holding body of a light source holding body for holding the light source group. A hole is provided in one of both ends of the mirror substrate, a slot is provided as a position adjusting means on the other, a protrusion is provided on one of the both ends of the light source holder, and the other The mirror mounting step includes: a step of locking the hole portion with the projection portion; a step of passing a screw through the position adjusting means; and the screw hole; A step of moving the mirror substrate so as to rotate the position adjusting means to adjust the position of the mirror substrate; and a step of fixing the mirror substrate and the light source holder by fastening the screw. The method of manufacturing a light source device according to claim 1, comprising: 3. The light source device according to claim 1, wherein the mirror group includes a plurality of mirrors arranged stepwise in parallel on an optical axis of a light beam emitted from the light source group. Method. 4. The mirror group is a strip-like mirror having the same number as the number of light sources in the light source group, and each mirror is disposed with the same inclination. The manufacturing method of the light source device in any one of. The said mirror group is comprised from the same number of mirrors as the number of the light sources in the said light source group, and each mirror is arrange | positioned by making the same inclination, respectively. A method for manufacturing the light source device according to claim 1. 6. The method of manufacturing a light source device according to claim 1, wherein the adhesive portion and the filler are an ultraviolet curable resin adhesive or a thermosetting resin adhesive. A light source group in which a plurality of light sources are arranged in a plane so as to form rows and columns; a collimator lens that converts each light into parallel light so as to enhance the directivity of each emitted light from each light source of the light source group ; A mirror group composed of a plurality of mirrors for reflecting the beam bundle region of each of the emitted lights that have passed through the collimator lens so as to be emitted at a predetermined angle, and the back surface of the mirror adjacent to the edge of the plurality of mirrors And a mirror substrate that supports a back surface of the mirror group connected by the adhesive portion via a filler, and the light beam reflected by the mirror group. A light source device comprising: a condensing lens that condenses the light. The light source device further includes a mirror group holding body for holding the mirror group, and both ends of the mirror substrate are provided with holes for locking the mirror group holding body on the one hand and the mirror group holding on the other hand. The light source device according to claim 7, further comprising an elongated hole that is a position adjusting unit that locks the mirror group holding body while making it possible to adjust the attachment position of the body. A light source device, a display element, a light source side optical system that guides light from the light source device to the display element, a projection side optical system that projects an image emitted from the display element onto a screen, and the light source device And a projector control means for controlling a display element, wherein the light source device is a light source device that emits red wavelength band light, a light source device that emits blue wavelength band light, and a light source device that emits green wavelength band light. A projector characterized in that at least one of the light source devices is the light source device according to claim 7 or 8.

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