projector

Abstract

To provide a projector which can project an image which is clear, and suppressed in a reflection of foreign matters.SOLUTION: A projector 1 comprises a light source 11 for emitting light, a pattern plate 20 having a projection pattern, a first lens component 21 including a light condensing lens 211 for collecting light emitted from the light source 11, and sending it to the pattern plate 20, and a second lens component 22 including a projection lens 221 for projecting a pattern of the pattern plate 20. The first lens component 21 and the second lens component 22 sandwiches and fixes the pattern plate 20 therein so as to seal it.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a projector, and more particularly to a projector for use in a vehicle interior. [Background technology]

[0002] Conventionally, a vehicle lamp has been known that includes a focusing lens that focuses light emitted from a light source, a light blocking member that partially transmits the light focused by the focusing lens, and a projection lens that projects the light that has passed through the light blocking member to form an illumination pattern (see Patent Document 1).

[0003] In the vehicle lamp described in Patent Document 1, a condenser lens, a filter, and a projection lens are housed in a housing, and are fixed by being fitted into a condenser lens groove, a filter groove, and a projection lens groove, respectively, of the housing. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2020-205237 A Summary of the Invention [Problem to be solved by the invention]

[0005] However, in the vehicle lamp described in Patent Document 1, the condenser lens, the filter, and the projection lens are each fixed in position by the housing, so the relative positioning accuracy of the condenser lens, the filter, and the projection lens is poor, and the projected image may become unclear. In addition, foreign matter such as dust may enter the space where the filter is installed from the outside through the gap between the condenser lens and the housing in the condenser lens groove, or through the gap between the projection lens and the housing in the projection lens groove, and the foreign matter may be reflected in the projected image.

[0006] An object of the present invention is to provide a projector that can project a clear image with reduced reflection of foreign matter. [Means for solving the problem]

[0007] In order to achieve the above object, one aspect of the present invention provides a projector as described below in [1] to [3].

[0008] [1] A projector comprising: a light source that emits light; a pattern plate having a pattern for projection; a first lens component including a focusing lens that collects the light emitted from the light source and sends it to the pattern plate; and a second lens component including a projection lens for projecting the pattern on the pattern plate, wherein the first lens component and the second lens component clamp and fix the pattern plate so as to seal it inside. [2] The projector described in [1] above, wherein the pattern plate has a transparent substrate and an opaque film on the transparent substrate having a pattern that constitutes the pattern, and the minimum width of the opaque film is less than 10 μm. [3] A projector as described in [1] or [2] above, wherein fine details contained in at least a part of the pattern of the pattern plate are not resolved in a focused projected image, and the fine details represent a brightness in the projected image that is between the brightness of the parts formed by the light-transmitting parts of the pattern and the brightness of the parts formed by the light-shielding parts of the pattern. Effect of the Invention

[0009] According to the present invention, it is possible to provide a projector that can project a clear image with reduced foreign matter reflection. [Brief description of the drawings]

[0010] [Figure 1] 1(a) and 1(b) are perspective views of a projector according to an embodiment of the invention viewed from different angles. [Diagram 2] FIG. 2(a) is a side view of a projector according to an embodiment of the present invention as viewed from the light extraction side, and FIG. 2(b) is a cross-sectional view of the projector cut along the cutting line AA shown in FIG. 2(a). [Diagram 3]FIG. 3 is an exploded perspective view of the projector according to the embodiment of the invention. [Figure 4] 4(a) to 4(d) are perspective views showing a process for assembling a first lens component, a handle plate, and a second lens component to components of a housing. [Diagram 5] FIG. 5(a) is a cross-sectional view of the housing component, the first lens component, and the second lens component taken along the cutting line BB shown in FIG. 4(d). [Figure 6] FIG. 6 is a vertical sectional view of one form of a handle plate according to an embodiment of the present invention. [Figure 7] FIG. 7(a) is a schematic diagram showing an example of a pattern on a pattern plate in an embodiment of the present invention, and FIG. 7(b) is a schematic diagram showing a projected image onto which the pattern of FIG. 7(a) is projected. [Figure 8] FIG. 8 is a vertical sectional view of another embodiment of the handle plate according to the present invention. [Figure 9] FIG. 9 is a schematic diagram for explaining the conditions under which total reflection occurs when the light-shielding portion of the handle plate is formed of a protrusion including two opposing inclined surfaces. [Figure 10] 10(a), (b), and (c) are schematic diagrams showing the optical paths of light that enters a pattern plate with angles θt of 90°, 140°, and 40°, respectively. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] [Embodiment] Figures 1(a) and (b) are perspective views of a projector 1 according to an embodiment of the invention viewed from different angles. Figure 2(a) is a side view of the projector 1 viewed from the light extraction side, and Figure 2(b) is a cross-sectional view of the projector 1 cut along the cutting line AA shown in Figure 2(a). Figure 3 is an exploded perspective view of the projector 1.

[0012] Projector 1 is primarily used inside a vehicle and is attached, for example, to a side panel, instrument panel, door, etc. of the vehicle interior, and projects images onto the door, floor mat, ceiling, decorative panels and decorative ornaments included in the instrument panel, door trim, etc.

[0013] The projector 1 includes a light source 11 that emits light, a pattern plate 20 having a pattern for projection, a first lens component 21 including a condenser lens 211 that collects the light emitted from the light source 11 and sends it to the pattern plate 20, and a second lens component 22 including a projection lens 221 for projecting the pattern of the pattern plate 20. In the projector 1, the first lens component 21 and the second lens component 22 clamp and fix the pattern plate 20 inside the first lens component 21 and the second lens component 22 so as to seal it.

[0014] The light source 11 is a light emitting element equipped with an LED chip, etc. The light source 11 is mounted on a circuit board 10, and a connector 12 for transmitting power and signals to the light source 11 is connected to the circuit board 10.

[0015] The circuit board 10 on which the light source 11 is mounted, the first lens component 21, the second lens component 22, and the handle plate 20 are housed in a housing 30 consisting of components 30a, 30b, and 30c. The housing 30 has an opening 301 for extracting light from the projection lens 221, and an opening 302 for connecting a connector of an external device to the connector 12. The housing 30 is made of resin such as polybutylene terephthalate (PBT) resin, polypropylene (PP) resin, or ABS resin.

[0016] Components 30a and 30b are fixed by snap-fitting protrusions 305 provided on both sides of component 30b into holes 304 provided in component 30a. Components 30a and 30c are fixed by snap-fitting protrusions 307 provided on both sides of component 30c into holes 306 provided in component 30a. Circuit board 10 is sandwiched and fixed between components 30a and 30c.

[0017] First lens component 21 has condenser lens 211, frame portion 212 having a box-like (e.g., rectangular parallelepiped) shape with one open side, and fixing portion 215 for fixing first lens component 21 to second lens component 22 and housing component 30b. Condenser lens 211 is located within a plane facing the open surface of frame portion 212. First lens component 21 is made of resin, such as polycarbonate (PC) resin or polymethyl methacrylate (PMMA) resin.

[0018] The second lens component 22 has a projection lens 221, a frame portion 222 having a box-like (e.g., rectangular parallelepiped) shape with one open side, and a fixing portion 225 for fixing the second lens component 22 to the first lens component 21 and the housing component 30b. The projection lens 221 is located within a plane facing the open surface of the frame portion 222. The second lens component 22 is made of a resin such as a polycarbonate resin or a polymethyl methacrylate resin.

[0019] In the projector 1, the first lens component 21 and the second lens component 22 are fixed in a state in which the opening surface of the frame portion 212 faces the opening surface of the frame portion 222, and the end surface 213, which is the edge of the opening surface of the frame portion 212, and the end surface 223, which is the edge of the opening surface of the frame portion 222, are in close contact over the entire circumference. This seals the space including the pattern plate 20 inside the first lens component 21 and the second lens component 22. Note that, in order to improve the close contact, it is preferable that the end surface 213 and the end surface 223 are polished.

[0020] When the first lens part 21 and the second lens part 22 are brought into close contact with each other, the parts 214 projecting inward from the four corners of the internal space of the frame part 212 and the parts 224 projecting inward from the four corners of the internal space of the frame part 222 sandwich and fix the four corners of the handle plate 20 from the front and back.

[0021] 4(a) to (d) are perspective views showing a process for assembling the first lens component 21, the handle plate 20, and the second lens component 22 to the component 30b of the housing 30. FIG.

[0022] 4(a) and (b), the second lens component 22 is assembled to the component 30b of the housing 30. The fixing portion 225 is fitted into the component 30b of the housing 30 with the opening surface of the frame portion 222 facing upward.

[0023] 4(b) and (c), the handle plate 20 is fitted into the opening surface of the frame portion 222 of the second lens component 22. The handle plate 20 is fitted into the opening surface of the frame portion 222 so as to be placed on the portion 224 inside the frame portion 222 of the second lens component 22.

[0024] 4(c) and (d), the first lens component 21 is assembled to the housing component 30b. With the opening surface of the frame portion 212 facing downward, the fixing portion 215 is fitted into the housing component 30b. At this time, the protrusions 226 provided on the fixing portion 225 of the second lens component 22 are fitted into the holes 216 provided in the fixing portion 215 of the first lens component 21. Furthermore, when the fixing portion 215 is fitted into the component 30b, the protrusions 217 provided on both side surfaces of the fixing portion 215 snap-fit ​​into the holes 303 provided in the component 30b.

[0025] FIG. 5(a) is a cross-sectional view of the component 30b of the housing 30, the first lens component 21, and the second lens component 22 taken along the cutting line BB shown in FIG. 4(d).

[0026] 5(a), the second lens component 22 compresses and elastically deforms a protrusion 308 provided on the inner bottom surface of component 30b from above, and receives an upward repulsive force from the protrusion 308. On the other hand, since the protrusion 217 of the first lens component 21 is caught in the hole 303, the first lens component 21 and the second lens component 22 are prevented from moving upward, and therefore the first lens component 21 and the second lens component 22 are fixed to component 30b.

[0027] FIG. 5(b) is a cross-sectional view of the first lens component 21, the second lens component 22, and the handle plate 20 taken along the cutting line CC shown in FIG. 4(d).

[0028] 5(b), first lens component 21 and second lens component 22 are fixed in a state where end face 213, which is the edge of the opening of frame 212, and end face 223, which is the edge of the opening of frame 222, are in close contact with each other, and the internal spaces of first lens component 21 and second lens component 22 are sealed. Also, handle plate 20 is fixed by being sandwiched between part 214 protruding inward from the four corners of the internal space of frame 212 and part 224 protruding inward from the four corners of the internal space of frame 222.

[0029] In the projector 1, the first lens component 21, the second lens component 22, and the pattern plate 20 are fixed in close contact with each other, so that the relative positioning accuracy of the condenser lens 211 included in the first lens component 21, the projection lens 221 included in the second lens component 22, and the pattern plate 20 is high. Therefore, it is possible to prevent the projected image from becoming unclear due to the relative positional deviation of the condenser lens 211, the projection lens 221, and the pattern plate 20.

[0030] In addition, since the internal spaces of the first lens component 21 and the second lens component 22 are sealed, it is possible to prevent foreign matter such as dust from entering the periphery of the handle plate 20. This makes it possible to prevent foreign matter from appearing in the projected image.

[0031] The method of fixing the first lens component 21, the second lens component 22, and the handle plate 20 in close contact with each other is not limited to the method utilizing a snap fit with the above-mentioned component 30b; for example, the first lens component 21 and the second lens component 22 may be fixed with an adhesive.

[0032] 6 is a vertical cross-sectional view of a pattern plate 20a, which is one embodiment of the pattern plate 20. The pattern plate 20a includes a transparent substrate 201 that transmits light from the light source 11, and an opaque film 202 that does not transmit light from the light source 11. The opaque film 202 has a predetermined opening pattern that constitutes the pattern of the pattern plate 20a, and has light-transmitting portions 203 that are openings and light-shielding portions 204 that are not openings.

[0033] The image projected by the projector 1 is composed of high-brightness areas having a pattern corresponding to the pattern of the light-transmitting portions 203 and low-brightness areas having a pattern corresponding to the pattern of the light-shielding portions 204 .

[0034] In order to form a fine opening pattern in the opaque film 202 and make the pattern of the pattern plate 20a fine, it is preferable to form the pattern by metal etching on the opaque film 202 made of a metal formed on the transparent substrate 201 made of glass. By forming the metal film by vapor deposition, a very thin (about 100 nm) opaque film 202 can be obtained, and the pattern can be formed with high precision by etching.

[0035] In this case, the opaque film 202 is, for example, a laminated film of an opaque film 202a made of CrO and an opaque film 202b made of Cr. Also, for example, the thicknesses of the opaque film 202, the opaque film 202a, and the opaque film 202b are 1.1 mm, 8 nm, and 62 nm, respectively, and the planar size of the pattern plate 20 is 8 mm × 8 mm.

[0036] When forming a pattern on an opaque film 202 made of metal deposited on a transparent substrate 201 made of glass, the minimum width of the patterned opaque film 202 (the minimum width of the light-shielding portion 204 having light-transmitting portions 203 formed on both sides) can be set to 1 μm or more and less than 10 μm, or more precisely, 1 μm or more and 5 μm or less.

[0037] Furthermore, if the pattern of the pattern plate 20a includes fine parts that exceed the resolution of the projection lens 221, the fine parts will not be resolved even in a focused projected image. Specifically, in the projected image, the boundary between the high-brightness area formed by the light-transmitting portion 203 and the low-brightness area formed by the light-shielding portion 204 will not be visible, and the high-brightness area and the low-brightness area will blend together, resulting in a visible area having a brightness between those brightness levels (brightness lower than the resolved high-brightness area and higher than the resolved low-brightness area).

[0038] In other words, by using the fine details contained in the pattern of the pattern plate 20a that are not resolved in a focused projected image, it is possible to express a brightness in the projected image that is between the brightness of the part formed by the light-transmitting part 203 and the brightness of the part formed by the light-shielding part 204.

[0039] Fig. 7(a) is a schematic diagram showing an example of a pattern on the pattern plate 20a, and Fig. 7(b) is a schematic diagram showing a projected image in which the pattern in Fig. 7(a) is projected. The line and space pattern (the second triangle from the left and the top surface of the cube) and the dot pattern (the third triangle from the left and the side surface of the cube) included in the pattern in Fig. 7(a) are fine patterns that exceed the resolution of the projection lens 221, and in the projected image shown in Fig. 7(b), the area formed by these fine patterns is visually recognized as a gray area with a brightness between the white of the area formed by the light-transmitting part 203 (the first triangle from the left and the front surface of the cube) and the black of the area (underlying part) formed by the light-shielding part 204. In this way, a gradation expression shown by the difference in brightness of the three triangles in Fig. 7(b) and a three-dimensional expression exemplified by the cube in Fig. 7(b) can be achieved.

[0040] Furthermore, if a fine pattern can be formed on the opaque film 202, the pattern plate 20 can be made smaller. Since the size of the projected image is the size of the pattern on the pattern plate 20 multiplied by the magnification factor of the optical system, if the pattern plate 20 can be made smaller, the magnification factor can be increased while maintaining the size of the projected image. Therefore, the distance between the pattern plate 20 and the projection lens 221 can be reduced (the magnification factor increases), and the projector 1 can be made smaller. That is, by making the pattern plate 20 smaller, the projector 1 can be made smaller while maintaining the size of the projected image. For example, the width W1 of the projector 1 in the optical axis direction can be set to 35 mm or less, the width W2 in the direction perpendicular to the optical axis direction can be set to 13 mm or less, and the angle of view can be set to 20° or more.

[0041] 8 is a vertical cross-sectional view of a handle plate 20b which is another embodiment of the handle plate 20. The handle plate 20b is made of a transparent resin that transmits light from the light source 11, and has, on one side, a light-transmitting portion 207 formed of a flat surface 205 and a light-shielding portion 208 formed of an inclined surface 206 inclined relative to the flat surface.

[0042] The light shielding portion 208 shields the light from the light source 11 by utilizing the total reflection of the light on the inclined surface 206. Therefore, the inclination angle of the inclined surface 206 is set to an angle at which the light perpendicularly incident on the handle plate 20b is totally reflected. Therefore, the light shielding portion 208 formed by the inclined surface 206 does not transmit the light. For example, when the handle plate 20b is made of polycarbonate (refractive index 1.6), total reflection occurs when the incident angle is 38.7° or more, and when the handle plate 20b is made of polymethyl methacrylate (refractive index 1.5), total reflection occurs when the incident angle is 41.8° or more.

[0043] The image projected by the projector 1 is composed of high-brightness areas having a pattern corresponding to the pattern of the light-transmitting portions 207 and low-brightness areas having a pattern corresponding to the pattern of the light-shielding portions 208 .

[0044] The handle plate 20b is formed by microfabrication of a plate-shaped resin molded product. Therefore, compared to the handle plate 20a, which requires complicated processes such as deposition of a metal film, formation of a resist pattern by photolithography, and etching, the handle plate 20b can be formed inexpensively.

[0045] The light shielding portion 208 is provided with a protrusion formed by an inclined surface 206. The protrusion formed by the inclined surface 206 is, for example, a linear protrusion with a triangular cross section formed by two opposing inclined surfaces 206, or a polygonal pyramid protrusion formed by three or more inclined surfaces 206. When the height of the protrusion is limited (for example, 30 μm or less) due to the transferability during molding of the handle plate 20b, the area of ​​the light shielding portion 208 can be ensured by arranging multiple protrusions having low heights in succession.

[0046] 9 is a schematic diagram for explaining the conditions for total reflection when the light shielding portion 208 of the pattern plate 20b is composed of a protrusion including two opposing inclined surfaces 206 (for example, a linear protrusion with a triangular cross section formed by the two opposing inclined surfaces 206, or a quadrangular pyramid protrusion). Here, the angle of incidence of the light that enters the pattern plate 20b perpendicularly to the first inclined surface 206 (assumed to be inclined surface 206a) is θ1, the angle of incidence of the light reflected by inclined surface 206a to the next inclined surface (assumed to be inclined surface 206b) is θ2, and the angle of the cross section of the apex of the protrusion is θ t Let us assume that.

[0047] In order for the light that enters the handle plate 20b perpendicularly to be totally reflected by the inclined surface 206a, when the handle plate 20b is made of polycarbonate, θ1 must be 38.7° or more. In this case, θ t When the handle plate 20b is made of polymethyl methacrylate, θ1 must be 41.8° or more. t will be less than 96.4°.

[0048] Furthermore, in order for the light totally reflected by the inclined surface 206a to be totally reflected by the inclined surface 206b, when the handle plate 20b is made of polycarbonate, θ2 needs to be 38.7° or more. In this case, θ t When the handle plate 20b is made of polymethyl methacrylate, θ2 must be 41.8° or more. t is greater than 87.9°.

[0049] Therefore, when the handle plate 20b is made of polycarbonate, in order to effectively block light at the light blocking portion 208, the angle θ of the cross section of the apex of the projection is set to 0.05 mm. t It is preferable to set the angle θ of the cross section of the apex of the projection to 85.8° or more and 102.6° or less. In addition, when the handle plate 20b is made of polymethyl methacrylate, in order to effectively block light at the light blocking portion 208, t It is preferable to set the angle to 87.9° or more and 96.4° or less.

[0050] FIG. 10(a) shows the angle θ t 1 is a schematic diagram showing the optical path of light that enters the pattern plate 20b with an angle of 90°. In this case, the light that enters the pattern plate 20b perpendicularly is incident on the inclined surface 206a at an incident angle of 45° and is totally reflected, and then is incident on the inclined surface 206b at an incident angle of 45° and is totally reflected, returning to the light source 11 side. t A protrusion with an angle of 90° can be formed with a common tool, so the angle t A particularly preferred value is 90°.

[0051] FIG. 10(b) shows the angle θ t 1 is a schematic diagram showing the optical path of light that enters the pattern plate 20b with an incident angle of 140°. In this case, the light that enters the pattern plate 20b perpendicularly enters the inclined surface 206a at an incident angle of 20°, and a part of the light is refracted at the inclined surface 206a and passes through the pattern plate 20b.

[0052] FIG. 10(c) shows the angle θ t 1 is a schematic diagram showing the optical path of light that enters the pattern plate 20b with an incident angle of 40°. In this case, the light that enters the pattern plate 20b perpendicularly is incident on the inclined surface 206a at an incident angle of 70° and is totally reflected, but then it is incident on the inclined surface 206b at an incident angle of 30°, and part of it is refracted at the inclined surface 206b and passes through the pattern plate 20b.

[0053] (Effects of the embodiment) In the projector 1 according to the embodiment of the present invention, the first lens component 21, the second lens component 22, and the pattern plate 20 are fixed in a state of close contact with each other, so that the relative positioning accuracy of the condenser lens 211 included in the first lens component 21, the projection lens 221 included in the second lens component 22, and the pattern plate 20 is high. Therefore, it is possible to prevent the projected image from becoming unclear due to the relative positional deviation of the condenser lens 211, the projection lens 221, and the pattern plate 20. In addition, since the internal spaces of the first lens component 21 and the second lens component 22 are sealed, it is possible to prevent the intrusion of foreign matter such as dust around the pattern plate 20. Therefore, it is possible to prevent the reflection of foreign matter in the projected image.

[0054] Although the embodiment of the present invention has been described above, the present invention is not limited to the above embodiment, and various modifications are possible without departing from the spirit of the invention. Furthermore, the components of the above embodiment can be combined in any manner without departing from the spirit of the invention.

[0055] In addition, the above-described embodiments do not limit the scope of the invention according to the claims. Also, it should be noted that not all of the combinations of features described in the embodiments are necessarily essential to the means for solving the problems of the invention. [Explanation of symbols]

[0056] 1 Projector 11 Light source 20 Pattern Plate 21 First lens component 211 Condenser Lens 212 Frame 22 Second lens component 221 Projection Lens 222 Frame 30 Case

Claims

1. A light source that emits light; a pattern plate having a pattern for projection; a first lens component including a focusing lens for collecting light emitted from the light source and transmitting the light to the handle plate; a second lens component including a projection lens for projecting a pattern of the pattern plate; Equipped with The first lens component and the second lens component are fixed to each other by sandwiching the handle plate therebetween so as to seal the handle plate therein, The pattern plate includes, in at least a portion of the pattern, a fine portion that is not resolved in a focused projected image and is so fine as to exceed the resolution of the projection lens; the fine portion expresses a brightness between a brightness of a portion formed by a light-transmitting portion of the pattern and a brightness of a portion formed by a light-shielding portion of the pattern in the projected image; projector.

2. A light source that emits light; a pattern plate having a pattern for projection; a first lens component including a condenser lens that collects light emitted from the light source and sends it to the handle plate, and a first frame portion having a first opening surface, the condenser lens being located on a surface of the first frame portion that faces the first opening surface; a second lens component including a projection lens for projecting a pattern of the pattern plate and a second frame having a second opening surface, the projection lens being positioned within a surface of the second frame facing the second opening surface; Equipped with The end face of the first frame portion, which is the edge of the first opening surface, and the end face of the second frame portion, which is the edge of the second opening surface, are bonded in a tight contact state, so that the handle plate is accommodated in the space within the first lens component and the second lens component, and the space is sealed. The handle plate is fixed by being sandwiched between a portion of the first frame portion protruding from a corner of the space and a portion of the second frame portion protruding from a corner of the space. projector.

3. The pattern plate has a transparent substrate and an opaque film having a pattern constituting the pattern on the transparent substrate, The minimum width of the opaque film is less than 10 μm; The projector according to claim 2 .

4. The pattern plate includes, in at least a portion of the pattern, a fine portion that is not resolved in a focused projected image and is so fine as to exceed the resolution of the projection lens; the fine portion expresses a brightness between a brightness of a portion formed by a light-transmitting portion of the pattern and a brightness of a portion formed by a light-shielding portion of the pattern in the projected image; The projector according to claim 2 .

Images