TWI461816B - Optical projection subsystem and method of manufacturing the same - Google Patents

Description

Optical projection subsystem and method of manufacturing same

An optical projector is used to project an image onto a surface for viewing by a crowd. Optical projectors include optical projector subsystems including lenses, filters, polarizers, light sources, image forming devices, and the like. Fixed front projection electronic projectors and rear projection electronic projectors are known for use in education, home theaters, and business meetings. Light sources are known to include black body lamps, gas discharge lamps, and solid state sources such as lasers, light emitting diodes (LEDs), and organic light emitting diodes (OLEDs). Head mounted displays (HMDs) are known for individual use. For mobile applications, it is necessary to miniaturize the optical projector in terms of volume and thickness and make the optical projector extremely power efficient while maintaining low power consumption, low cost, and high image quality. However, the large size and high power consumption of existing optical projection subsystems limits the effort to build true portable projectors. There is a need for a method and optical projection subsystem that provides miniaturization and efficiency to project good quality images in a cost effective manner.

It is disclosed as a projection subsystem. The projection subsystem includes an illumination subsystem that provides an incoherent, uniformed beam of light. The illumination subsystem includes a collection lens, a collimator, and at least one solid state light emitter. The solid state light emitter receives electrical power levels and can be coupled to a heat sink.

The projection subsystem includes an image forming device. The image forming apparatus receives the image data and the polarized light beam. The image forming apparatus provides an image to the refractor.

The projection subsystem includes a projection lens assembly. The projection lens assembly receives an image from the refractor and provides an image projection beam having a luminous flux level.

According to one aspect, the projection subsystem has a portability effect comprising a volume of less than 14 cubic centimeters and a thickness of less than 14 millimeters.

For mobile applications, it is necessary to project an image with a diagonal size of 12 cm or more under ambient lighting conditions. For good viewing, it typically requires a flux of at least 3 lumens and a contrast ratio of at least 30:1. . Additional desirable features that provide good image quality can include a large number of parsing pixels, wide color gamut, and image uniformity.

For mobile applications, "portability" will be defined as the combined measurement of the small size, high power efficiency, and light output of the projection subsystem. 1 is a diagram 100 illustrating two aspects of the portability of a projection subsystem. The term "projection subsystem" refers to a source of light, an image forming apparatus, and associated refractive or reflective optical components (such as lenses, mirrors, or beam splitters) for providing a projected optical image. The vertical axis 102 represents the power efficiency of the projection subsystem in lumens for 1 watt of electrical power applied to the light source. The horizontal axis 104 represents the volume of the projection subsystem. The portability 108 increases as efficiency increases and increases as volume decreases. The projection subsystem has increased portability when power efficiency is high and volume is small.

The desired features of the projection subsystem include high level of luminous flux in the projected image, large screen size, high contrast, large pixel content, and wide color gamut. Figure 1 illustrates a method of comparing some of these features of different optical systems. As described in the presently disclosed embodiments, a projection subsystem having an incoherent light source can provide an available combination of desired features.

As illustrated in Figure 1, representative conventional projection subsystems A, C, D, and E are evaluated in terms of power efficiency and size and mapped onto the graph 100. Subsystem A and Subsystem C are generally superior to D and E in terms of power efficiency and size, but use coherent laser sources that are low cost, low image quality due to laser spots and potential eyes at high cost There are deficiencies in safety issues, especially in the event of electrical or mechanical failure. Subsystem D and Subsystem E use non-coherent LED sources that overcome the drawbacks of laser-based systems, but are relatively large, less power efficient, or have poor power efficiency and size, resulting in limited Carrying effect. An exemplary projection subsystem of the present invention is shown in FIG. 100 as projection subsystem B, which uses an incoherent light source and has a size smaller than that of subsystem D and subsystem E and greater than the efficiency of subsystem D and subsystem E. effectiveness.

When the projector design is miniaturized or scaled down, the ambient lighting level in the projection environment is not scaled down. A sufficient projected optical power level is required to provide a projected image that is sufficiently bright for the viewer population in the presence of ambient light. For example, if the size of the illumination source is to be miniaturized and the same electrical power level is to be applied to a smaller illumination source, an increased temperature rise will be encountered in the smaller illumination source, which can result in overheating. The optical efficiency of the projector optics needs to be optimized to scale down the electrical power level to avoid overheating the small illumination source without reducing the luminous flux of the projected image output. While high power solid state lasers that produce highly collimated, coherent light can improve power efficiency, the use of coherent light can create speckle that reduces the quality of the projected image. Also, the use of laser light raises concerns about eye safety, especially in the event of electrical or mechanical failure.

As illustrated in the following embodiments, the optical assembly is assembled in a modified combination to achieve the desired high level of luminous flux at low level electrical power in a small projection subsystem. Avoid the use of coherent light sources. Enhances the portability of the projection subsystem. In particular, many of the optical losses typically associated with light as it passes through the air between conventional projector optics components are avoided.

The projection subsystem disclosed herein with high portability can operate in region 110 in FIG. Region 110 is limited to a volume of no more than 14 cubic centimeters and an efficiency of no less than 1 watt of 3.8 lumens.

Another measure of portability includes the thickness of the projection subsystem along its thinnest axis. The projection subsystem is best suited for use in pocket-type devices when the projection subsystem has a thickness of less than 14 mm along the thickness axis. Another aspect of portability is luminous flux. When the luminous flux is at least 3 lumens, the projection subsystem is best suited for use in pocket-type devices.

FIG. 2 illustrates projection subsystem 200. Projection subsystem 200 is suitable for projecting static or video images from small electronic systems such as cell phones, personal digital assistants (PDAs), and global positioning system (GPS) receivers. Projection subsystem 200 receives electrical power and image data from a small electronic system (not illustrated in Figure 2) in which projection subsystem 200 is embedded. The projection subsystem 200 is adapted for use in component parts of small projector accessories that display computer video. The projection subsystem 200 is adapted to be small enough to be carried in a system such as a shirt pocket when not in use. The image projected by projection subsystem 200 can be projected onto a reflective projection screen, a light painted wall, a whiteboard or sheet of paper, or other known projection surface. Projection subsystem 200 can be embedded, for example, in a portable computer or mobile phone such as a laptop.

Projection subsystem 200 includes a light engine 202. Light engine 202 provides a beam of light 204. The light engine includes a collection lens 206, a collimator 208, and a solid state light emitter 210. According to one aspect, the collecting lens 206 comprises a super hemispherical ball lens. According to one aspect, the super hemispherical ball lens is configured as taught in U.S. Patent Publication No. US 2007/0152231.

Solid state light emitter 210 receives electrical power 212 having an electrical power level. The solid state emitter 210 is thermally coupled to the heat sink 214. A solid state light emitter provides an emitter beam having a transmitter flux level. According to one aspect, beam 204 contains incoherent light. According to another aspect, beam 204 includes illumination of a portion of the focused image of solid state light emitter 210. According to yet another aspect, solid state light emitter 210 includes one or more light emitting diodes (LEDs). According to another aspect, the collecting lens 206 comprises a hemispherical spherical lens. According to another aspect, the collimator 208 includes a focusing unit, the focusing unit includes: a first Fresnel lens having a first non-polyhedron for receiving the first non-collimated beam and a first multi-faceted side for emitting a collimated beam; and a second Fresnel lens having a second non-polyhedral side for substantially directly receiving the collimated beam and for emitting an output beam Two sides. According to another aspect, solid state light emitter 210 can be configured as shown in U.S. Provisional Application Serial No. 60/820,883. According to yet another aspect, the light engine 202 can be configured as shown in U.S. Provisional Application Serial Nos. 60/820,887, 60/820,888, 60/821,032, 60/838,988.

Projection subsystem 200 includes a refractive body 220. Refractor 220 receives beam 204. The refractive body 220 provides a polarized beam 222. Refractor 220 includes an internal polarizing filter 224. One of the beams 204 is reflected by the internal polarizing filter 224 via the polarized component to form a polarized beam 222. According to one aspect, U.S. Patent Publication No. US 2007/0023941 to Duncan et al., U.S. Patent Publication No. US 2007/0024981 to Duncan et al, and US Patent Publication No. US 2007/0085973 A1 to Duncan et al. Refractors are formed or utilized in one or more aspects of U.S. Patent Publication No. US 2007/0030456. The refractive body 220 includes a first outer lens surface 226 and a second outer lens surface 228. According to one aspect, the outer lens surfaces 226, 228 have curved lens surfaces and have non-zero lens optical energy. According to another aspect, the outer lens surface 226 includes a convex lens surface adapted to maintain a small volume of the projection subsystem 200. According to another aspect, the outer lens surfaces 226, 228 are flat. According to one aspect, the refractive body 220 includes plastic resin material bodies 230, 232 on opposite sides of the internal polarizing filter 224. According to another aspect, the internal polarizing filter 224 comprises a multilayer optical film. According to another aspect, the refractive body 220 includes a multifunctional optical component that acts as a polarizing beam splitter and a lens. By combining the polarizing beam splitter and lens function in the multifunctional refractor, losses that would otherwise occur at the air interface between the individual beam splitters and the lens can be avoided.

Projection subsystem 200 includes an image forming device 236. Image forming device 236 receives image data on electrical input bus 238. Image forming device 236 receives polarized light beam 222. The image forming device 236 selectively reflects the polarized light beam 222 based on the image data. Image forming device 236 provides an image 240 having a polarized light that is rotated relative to the polarized light of polarized beam 222. Image forming device 236 provides image 240 to refractor 220. Image 240 passes through internal polarizing filter 224. According to an aspect, the image forming apparatus 236 includes a liquid crystal on silicon (LCOS) device.

Projection subsystem 200 includes a projection lens assembly 250. Projection lens assembly 250 includes a plurality of lenses that are schematically indicated at 252, 254, 256, 258, 260. Projection lens assembly 250 receives image 240 from refractor 220. Projection lens assembly 250 provides an image projection beam 262 having a projected luminous flux suitable for viewing. According to one aspect, the projected luminous flux is not less than 3 lumens. According to another aspect, the ratio of projected luminous flux to electrical power level is at least 1 watt and 3.8 lumens. According to another aspect, the ratio of projected luminous flux to electrical power level is at least 7 lumens per watt. According to another aspect, the ratio of projected luminous flux to electrical power level is at least 10 lumens per watt. According to another aspect, the light collection efficiency ratio is at least 38.5%. The light collection efficiency ratio is defined as the ratio of the polarized light flux impinging on the effective surface of the image forming apparatus 236 to the luminous flux emitted from the unpolarized solid state light emitter 210.

According to another aspect, projection subsystem 200 has an electrical power level of no more than 3.6 watts. According to another aspect, projection subsystem 200 has a volume of less than 14 cubic centimeters. According to another aspect, projection subsystem 200 has a thickness of less than 14 millimeters.

According to another aspect, projection subsystem 200 has an F number of less than 2.4. According to another aspect, the projection subsystem has an ANSI contrast ratio of at least 30:1. According to another aspect, the projection subsystem has an ANSI contrast ratio of at least 50:1. According to another aspect, the projection subsystem has an on/off contrast ratio of at least 100:1.

FIG. 3A illustrates projection subsystem 300. Projection subsystem 300 is similar to projection subsystem 200 except that synthetic optical device 302 is included in projection subsystem 300. The same reference numerals as used in FIG. 2 in FIG. 3A denote the same or similar features. In other aspects, projection subsystem 300 is similar to projection subsystem 200. Synthetic optical device 302 changes the aspect ratio of beam 304. The synthetic optical device 302 changes the beam shape to adapt the first aspect ratio in the light engine 202 to a second, different aspect ratio in the refracting body 220. According to one aspect, the first aspect ratio is 1:1 and the second aspect ratio is 16:9. According to another aspect, the first aspect ratio is 1:1 and the second aspect ratio is 4:3. According to one aspect, the second aspect ratio matches the aspect ratio of image forming device 236. According to one aspect, as illustrated in Figure 3A, the synthetic optical device 302 includes a synthetic lens. According to another aspect illustrated in Figure 3B, the composite surface 306 provided on the refractive body 320 acts as a synthetic optical device. In other aspects, the refractive body 320 is similar to the refractive body 220 of Figure 3A.

According to another aspect, the polarizing filter can be positioned at position 330 or position 332 in Figure 3A. The polarizing filter at position 330 or position 332 enhances the optical contrast ratio of optical subsystem 300. According to one aspect, the polarizing filter positioned at locations 330, 332 comprises a multilayer optical film.

4 illustrates a perspective view of the projection subsystem 300 of FIG. Projection subsystem 300 has a thickness 402. Projection subsystem 300 has a cross-sectional area 400 that is indicated by a flat surface drawn perpendicular to thickness 402. The cross-sectional area 400 includes the area of the components 206, 208, 236, 220, 250, 302 and the intervening air space between the components carrying the available light. Projection subsystem 300 has a volume that is a mathematical product of thickness 402 and cross-sectional area 400.

5A, 5B illustrate portions of projection subsystems 500, 510 that are similar to projection subsystem 200 or 300. Projection subsystem 500 includes a filter 502. Filter 502 is adjacent to collimator 208. According to one aspect, the filter 502 includes an optical assembly that is separate from the collimator 208. According to another aspect, the filter 502 includes a filter layer on the collimator 208. According to one aspect, collimator 208 is interposed between filter 502 and lens 206 as illustrated in FIG. 5A. According to another aspect illustrated in FIG. 5B, filter 504 is interposed between collimator 208 and lens 206. Filters 502, 504 include a blue blocking filter that also blocks ultraviolet (UV) radiation. The blue blocking filter blocks the blue and ultraviolet light that tends to degrade the refractive optical device while passing the portion of the blue spectrum that needs to be present in the projected image. Filter 502 or filter 504 blocks unwanted light from reaching refractor 220.

5C, 5D illustrate portions of projection subsystems 520, 540 that are similar to projection subsystem 200 or 300. Projection subsystem 520 includes a filter 522. Filter 522 is positioned between refractor 220 and projection lens assembly 250. Projection subsystem 540 includes a refractor 220A that includes a filter 542 adjacent to polarizing filter 224. The filter 542 is positioned between the polarizing filter 224 and the plastic resin body 230. Filters 522, 542 include a polarizing filter. The polarizing filters 522, 542 increase the contrast of the projected image. In accordance with an aspect, the projection subsystem of FIG. 5D is described in U.S. Patent Application Serial No. 11/457,599, entitled,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,

6 illustrates projection subsystem 600, which is similar to projection subsystem 600 except that projection subsystem 600 includes a plate fin 602 and projection subsystem 300 of FIG. 4 includes a heat sink 214 having protrusions such as fins or pins. Projection subsystem 300 in FIG. In other aspects, projection subsystem 600 is similar to projection subsystem 300. According to one aspect, the plate fin 602 has a lower plate surface 604 that is exposed to an outer package of a pocket-type electronic package such as a cell phone, personal digital assistant (PDA), global positioning system (GPS), or the like. At the surface. According to another aspect, the plate fins 602 are in thermal contact with other components in the electronic device to dissipate heat. According to another aspect, during use, the lower plate surface 604 can be placed in contact with an attached external heat sink for extended use.

7 illustrates projection subsystem 700, which is similar to projection subsystem 300 of FIG. 3A except that projection subsystem 700 includes a polarizing film 702 disposed along the optical path between collection lens 206 and refractor 220. . According to an aspect, as illustrated in FIG. 7, the polarizing film 702 is disposed between the collimator 208 and the refractive body 220. The polarizing film 702 reflects the polarized light toward the reflective surface of the solid state light emitter 210 to provide light recycling. The inclusion of a polarizing film 702 increases the luminous flux of the projection subsystem. According to one aspect, the polarized light recirculation is as described in U.S. Patent Application Serial No. 11/772,609, filed on July 2, 2007.

FIG. 8 illustrates a projection subsystem 800 similar to the projection subsystem of FIGS. 3A, 7. Projection subsystem 800 includes a housing 802 that surrounds at least a portion of optical components 206, 208, 702, 302, 220 and protects the surface of the optical component from contaminants and moisture. According to an aspect, the housing 802 can include an air filter 806. Air filter 806 confines air flow, filters out contaminants and equalizes the pressure between the interior of outer casing 802 and the surrounding atmosphere. According to one aspect, the air filter 806 includes a desiccant 808 that reduces the humidity within the outer casing 802. According to another aspect, the housing 802 serves for mechanical mounting of the optical components.

The outer casing 802 is coupled to the lens assembly guide tube 804. Projection lens assembly 250 is slidably mounted in guide tube 804. Projection lens assembly 250 includes an actuating lever 810 that is mechanically actuatable to move the position of projection lens assembly 250 relative to image forming device 236. The movement of the projection lens assembly 250 includes a focus adjustment. According to one aspect, the projection lens assembly 250 fits tightly into the guide tube 804 to provide a seal that prevents contaminants from entering the housing 802. According to another aspect, one or more O-rings (not illustrated) are provided between the projection lens assembly and the guide tube 804 to provide a seal. According to yet another aspect, a bellows (not illustrated) is provided between one end of the projection lens assembly 250 and the guide tube 804 to provide a seal.

Figure 9 illustrates a perspective view of a projection subsystem 900 similar to the projection subsystem shown in Figure 2. Projection subsystem 900 includes a solid state light emitter (not visible in Figure 9) that is connected to an electrical power source by electrical leads 902, 904. The solid state light emitter is thermally coupled to the heat sink 906. Projection subsystem 900 includes a collection lens 908. The projection subsystem 900 includes an image forming device 912, a refractor 914, and a projection lens 916.

FIG. 10A illustrates a light emitting diode 1000 that acts as an exemplary solid state light emitter, such as solid state light emitter 210 in FIG. The light emitting diode 1000 is connected to electrical power via bonding wires 1002, 1004. The light emitting diode 1000 includes light emitting regions 1008, 1010, 1012, 1014, and 1016. Other regions of the light emitting diode 1000, such as regions 1018, 1020, 1022, 1024, 1026, 1028, contain dark regions that include electrical conductors and that do not produce light. The image of the light-emitting diode 1000 is thus a pattern of a region where light is generated and a region where light is not generated. For use in projection, an image that is relatively uniform in brightness, such as illustrated in Figure 10B, is required. According to one aspect, a uniform brightness is provided as taught in U.S. Patent Publication No. 2007/0153397, entitled "PROJECTION SYSTEM WITH BEAM HOMOGENIZER".

Figure 11A illustrates an example of installing an optical component in a projection subsystem. The molding assembly 1100 includes an optical portion 1102 along the optical axis 1104 and a mounting flange portion 1106 that is molded as a unitary structure with the optical portion 1102. Optical portion 1102 includes a lens, however, any of the optical components of the projection subsystem can be used in place of the lens. The molded component is molded from a refractive material such as a transparent plastic resin. The mounting flange portion 1106 has rims 1108, 1110 that are shaped to mate with the flanges of adjacent molding components. The rims may be attached to one another by friction fit, snap fit, gluing, screwing or other known attachment methods for plastic resin molded components.

Figure 11B illustrates an example of installing an optical component in a projection subsystem. The optical assembly 1120 is retained in the grooves 1122, 1124 of the mating mold halves of the mounting tube 1126. A plurality of optical components are mounted in the mounting tube. Mounting tube 1126 is assembled along parting line 1128. Optical portion 1120 includes a lens, however, any of the optical components of the projection subsystem can be similarly mounted in place of the lens.

Figure 11C illustrates an example of installing an optical component in a projection subsystem. The optical assembly 1130 is retained in the groove 1132 of the mounting channel 1134. The cover 1136 is fastened to the mounting channel. A plurality of optical components are mounted in the mounting channel 1134. Mounting channel 1134 and cover 1136 are assembled along parting line 1138. Optical portion 1130 includes a lens, however, any of the optical components of the projection subsystem can be similarly mounted instead of a lens.

Figure 11D illustrates an example of a combination of a refractive body 1150 (such as the refractive body 220 of Figure 2) molded with a mounting flange rim 1152, 1154, 1156 similar to the rim shown in Figure 11A.

12A, 12B illustrate an alternate embodiment of a projection subsystem having portability capabilities as described above. 12A illustrates a projection subsystem 1202 that includes a light engine 1204, an image forming device 1206, and a projection lens assembly 1208. Image forming device 1206 includes a transmissive image forming device. 12B illustrates a projection subsystem 1222 that includes a light engine 1224, an image forming device 1226, a composite lens 1228, and a projection lens assembly 1230. Image forming device 1226 is a reflective image forming device (such as an array of deflectable mirror pixels) and does not require polarized light for its operation.

Instance

A projection subsystem similar to that of Figures 7 and 9 having a refractor similar to Figure 3B is constructed. The solid state light emitter is a white LED made of blue InGaN die with part number C450-EZ1000-S30000 plus an isoform yellow phosphor produced by Cree, Inc. (4600 Silicon Drive, Durham, NC 27703). The concentrating lens and its coupling to the LED are described in U.S. Patent Publication No. US 2007/0152231. The collimator is a Fresnel lens having a non-polyhedral side for receiving a non-collimated beam and a multifaceted side for emitting a collimated beam. The refractor is a molded plastic polarized beam splitter (PBS) as described in U.S. Patent Publication No. US 2007/0024981. Reflective polarizing films (one in PBS and one shown as element 702 in Figure 7) are sold by 3M Company (St. Paul, MN 55144) under the trade name "VIKUITI" advanced polarizing film (APF). Manufacturing. The image forming apparatus is an LCOS microdisplay with internal red, green and blue filters manufactured by Himax Display (2nd Floor, No. 26, Ziyu Road, Shugu Road, Xinshi Township, Tainan County, Taiwan), part number HX7007ATBFA.

The measurements of dimensions and performance are summarized in the table below, where IEC is an abbreviation for the International Electrotechnical Commission.

While the invention has been described with respect to the preferred embodiments embodiments illustrated embodiments

100. . . Figure

102. . . Vertical axis

104. . . Horizontal axis

108. . . Portability

110. . . region

200. . . Projection subsystem

202. . . Light engine

204. . . beam

206. . . Collecting lens

208. . . Collimator

210. . . Solid state light emitter

212. . . Electric power

214. . . heat sink

220. . . Refractive body

220A. . . Refractive body

222. . . Polarized beam

224. . . Internal polarizing filter

226. . . First outer lens surface

228. . . Second outer lens surface

230. . . Plastic resin body

232. . . Plastic resin body

236. . . Image forming equipment

238. . . Electric input bus

240. . . image

250. . . Projection lens assembly

252. . . lens

254. . . lens

256. . . lens

258. . . lens

260. . . lens

262. . . Image projection beam

300. . . Projection subsystem

302. . . Synthetic optical equipment

304. . . beam

306. . . Synthetic surface

320. . . Refractive body

330. . . position

332. . . position

400. . . Cross-sectional area

402. . . thickness

500. . . Projection subsystem

502. . . filter

504. . . filter

510. . . Projection subsystem

520. . . Projection subsystem

522. . . filter

540. . . Projection subsystem

542. . . filter

600. . . Projection subsystem

602. . . Plate diffuser

604. . . Lower plate surface

700. . . Projection subsystem

702. . . Polarized film

800. . . Projection subsystem

802. . . shell

804. . . Lens assembly guide tube

806. . . air filter

808. . . Desiccant

810. . . Actuating lever

900. . . Projection subsystem

902. . . Electric wire

904. . . Electric wire

906. . . heat sink

908. . . Collecting lens

912. . . Image forming equipment

914. . . Refractive body

916. . . Projection lens

1000. . . Light-emitting diode

1002. . . Bonding wire

1004. . . Bonding wire

1008. . . Luminous area

1010. . . Luminous area

1012. . . Luminous area

1014. . . Luminous area

1016. . . Luminous area

1018. . . region

1020. . . region

1022. . . region

1024. . . region

1026. . . region

1028. . . region

1100. . . Molded component

1102. . . Optical part

1104. . . Optical axis

1106. . . Mounting flange

1108. . . rim

1110. . . rim

1120. . . Optical component

1122. . . Trench

1124. . . Trench

1126. . . Mounting tube

1128. . . Parting line

1130. . . Optical component

1132. . . Trench

1134. . . Installation channel

1136. . . cover

1138. . . Parting line

1150. . . Refractive body

1152. . . Mounting flange rim

1154. . . Mounting flange rim

1156. . . Mounting flange rim

1202. . . Projection subsystem

1204. . . Light engine

1206. . . Image forming equipment

1208. . . Projection lens assembly

1222. . . Projection subsystem

1224. . . Light engine

1226. . . Image forming equipment

1228. . . Synthetic lens

1230. . . Projection lens assembly

1 is a diagram 100 illustrating qualitative measurements of the portability of a projection subsystem.

Figure 2 illustrates the projection subsystem.

Figure 3A illustrates a projection subsystem including a synthetic optical device.

Figure 3B illustrates a projection subsystem including a composite surface on a refractive body.

Figure 4 illustrates a perspective view of the projection subsystem of Figure 3A.

Figures 5A, 5B illustrate portions of a projection subsystem that includes a blue blocking filter.

Figures 5C, 5D illustrate portions of a projection subsystem that includes a polarizing filter that changes image contrast.

Figure 6 illustrates a projection subsystem having a plate fin.

Figure 7 illustrates a projection subsystem including light recycling.

Figure 8 illustrates a projection subsystem including a housing.

Figure 9 illustrates a perspective view of the projection subsystem.

Fig. 10A illustrates a light emitting diode.

Figure 10B illustrates an image formed by the light emitted from the light emitting diode of Figure 10A via an optical system.

11A, 11B, 11C, and 11D illustrate an example of mounting an optical component in a projection subsystem.

12A, 12B illustrate an alternate embodiment of a projection subsystem.

200. . . Projection subsystem

202. . . Light engine

204. . . beam

206. . . Collecting lens

208. . . Collimator

210. . . Solid state light emitter

212. . . Electric power

214. . . heat sink

220. . . Refractive body

222. . . Polarized beam

224. . . Internal polarizing filter

226. . . First outer lens surface

228. . . Second outer lens surface

230. . . Plastic resin body

232. . . Plastic resin body

236. . . Image forming equipment

238. . . Electric input bus

240. . . image

250. . . Projection lens assembly

252. . . lens

254. . . lens

256. . . lens

258. . . lens

260. . . lens

262. . . Image projection beam

Claims (23)

A projection subsystem comprising: a light engine providing a light beam, the light engine comprising a collecting lens, a collimator and at least one solid incoherent light emitter, the at least one solid incoherent light emitter receiving a The image forming device provides an image; the image forming device receives image data and receives at least one component of the light beam; and the image forming device provides an image; a projection lens assembly that receives the image and provides an image projection beam having a projected light flux level; and the projection subsystem has a portability function comprising a luminous flux and electrical power level of at least 1 watt of 3.8 lumens The ratio, and a projection subsystem volume of less than 14 cubic centimeters. The projection subsystem of claim 1, and further comprising: a refractor comprising an internal polarizing filter, the refractor receiving the beam and providing the image forming apparatus with a component of the polarized light of the beam. The projection subsystem of claim 2, wherein the projection subsystem comprises a thickness of less than 14 mm. The projection subsystem of claim 2, and further comprising at least one lens surface adjacent to the image forming apparatus, the at least one lens surface having a non-zero lens optical energy. The projection subsystem of claim 4, wherein the lens surface comprises a curved surface of the refractive body. The projection subsystem of claim 2, wherein the portability function comprises a portability limitation selected from the group consisting of: an electrical power of less than 3.6 watts, and a projected luminous flux level of at least 7 lumens per watt The ratio to the electrical power level and the ratio of the projected luminous flux level to the electrical power level of at least 10 lumens per watt. The projection subsystem of claim 2, and further comprising the heat sink. The projection subsystem of claim 2, wherein the refractive body comprises a body of plastic resin material on opposite sides of the internal polarizing filter. The projection subsystem of claim 2, wherein the internal polarizing filter comprises a multilayer optical film. The projection subsystem of claim 2, further comprising a reflective polarizer disposed adjacent to the collimator. The projection subsystem of claim 2, comprising a synthetic optical surface that adjusts an aspect ratio of the image projection beam. A projection subsystem comprising: a light engine providing a light beam, the light engine comprising a collecting lens, a collimator and at least one solid incoherent light emitter, the at least one solid incoherent light emitter receiving a The image forming device provides an image; the image forming device receives image data and receives at least one component of the light beam; and the image forming device provides an image; a projection lens assembly that receives the image and provides an image projection beam having a projected light flux level; and the projection subsystem has a portability function, wherein the electrical power level Less than 3.6 watts, a projection subsystem volume is less than 14 cubic centimeters and a projection subsystem thickness is less than 14 millimeters. The projection subsystem of claim 12, wherein the portability capability comprises a ratio of the luminous flux level of at least 1 watt of 3.8 lumens to the electrical power level. The projection subsystem of claim 12, wherein the collection lens comprises a hemispherical spherical lens. The projection subsystem of claim 12, wherein the solid state incoherent light emitter comprises at least one light emitting diode having a non-uniform region of higher light emission and lower light emission, and the local focus fill fills the region having lower light emission To increase the uniformity of lighting. The projection subsystem of claim 12, further comprising a reflective polarized light recirculator disposed adjacent to the collimator. A projection subsystem of claim 12, comprising a synthetic optical surface that receives the beam and shapes the beam to change an aspect ratio of the beam. A method of fabricating an optical projection subsystem, comprising: providing a light beam from a light engine, the light engine comprising a collecting lens, a collimator, and at least one solid incoherent light emitter, the at least one solid incoherent The light emitter receives an electrical power level and can be coupled to a heat sink and provides a light beam having a light flux level of the emitter; receiving at least one component of the light beam at an image forming apparatus that receives the image data, and providing a light source An image from the image forming apparatus; receiving the image at a projection lens assembly and providing a projection An image projection beam of a luminous flux level; and providing a portability function comprising a ratio of a luminous flux to an electrical power level of at least 1 watt of 3.8 lumens, and a projection subsystem volume of less than 14 cubic centimeters. The method of claim 18, and further comprising: receiving the beam at a refractor comprising an internal polarizing filter, the refractor providing the image forming apparatus with a component of the polarized light of the beam. The method of claim 18, and configuring and selecting the size of the optical components such that the projection subsystem has a volume of no more than 14 cubic centimeters. The method of claim 18, and providing reflective polarized light recycling to provide a light collection efficiency ratio of at least 38.5%. The method of claim 19, and providing a synthetic optical surface adjacent to the refractive body, the synthetic optical surface shaping an aspect ratio of the image beam. The method of claim 18, and providing a focus adjustment comprising one of a spacing between the projection lens assembly and the image forming device.