Free-Form Fold Mirror for Rear Projection Simulators
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Solution Overview
Problem
Flat fold mirrors in rear projection simulator systems result in uneven resolution and brightness, particularly near the edges of the projected image due to the expanding light cone, which is exacerbated by non-flat screens.
Innovation Solution
A free-form fold mirror with non-planar portions, including curved and flat sections, is interposed between the projector and screen to uniformly distribute projector light, using optical ray mapping and ray tracing to design the mirror's shape, ensuring consistent pixel density and resolution across the image.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a flat fold mirror is used to reduce floor space or ceiling height, then the system footprint is reduced, but the image resolution and brightness become uneven near the edges of the projected image
Solution Approach 1:
The fold mirror transitions from a uniform flat surface to a non-uniform surface with different curvature zones. The mirror includes a first curved portion with concave cross-sectional shape, a second curved portion with convex cross-sectional shape, and flat portions positioned between them. Each region of the mirror surface is locally optimized to redirect light rays from different areas of the projector, ensuring uniform pixel density and resolution across the entire projected image while maintaining the space-saving fold mirror configuration.
2Device complexity
If a flat fold mirror is used to redirect light, then the system complexity is reduced, but the brightness and resolution uniformity deteriorate due to expanding light rays on non-flat screens
Solution Approach 1:
The fold mirror incorporates curved portions with specific cross-sectional shapes to optically compensate for the expanding light cone. The first curved portion has a concave cross-sectional shape that converges diverging light rays, while the second curved portion has a convex cross-sectional shape that redirects light to achieve uniform illumination. This curvature design ensures that pixel density and brightness remain consistent across the projected image, particularly near the edges, while maintaining a relatively simple single-mirror structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The free-form fold mirror achieves uniform image resolution and brightness, reducing the workload on automatic alignment systems and allowing for a smaller system footprint while maintaining high-definition image projection.
Implementation Method 1
A free-form fold mirror is interposed between the projector and the display screen. The free-form mirror includes a first curved portion and a first flat portion... the first curved portion is positioned to affect an edge or boundary portion of an image projected by the projector
Data Source
Figure 1
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Figure 3A~3B
AI summary
The present invention provides a rear projection simulator system with a free-form fold mirror. The system includes a high definition projector and a curved screen. The free-form fold mirror is interposed between the projector and the screen. The free-form fold mirror includes one or more non-planar (e.g., curved) portions to eliminate or reduce loss of resolution of the projected image near the edges or boundaries of the image.