Freeform Optical Element for Projector Pixel Remapping
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Solution Overview
Problem
Commercially available projector systems suffer from inefficient pixel distribution due to their rectangular, square-pixel projection frustum, leading to poor utilization and suboptimal visual performance, especially in applications requiring a spherical field of view, as existing lens systems like fish-eye and anamorphic lenses have limited tolerance for pixel adjustment and result in unsatisfactory projection quality.
Innovation Solution
A device interposed between a projector and an imaging surface, utilizing a combination of refractive and reflective optical surfaces, including a thin glass mirror, to optically remap projected pixel locations, allowing for adjustment to maximize pixel utilization and distribution, thereby achieving optimal visual performance with minimal aberration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rectangular, square-pixel projection frustum is used, then the projector structure is simple and commercially available, but pixel utilization efficiency deteriorates and visual performance becomes suboptimal
Solution Approach 1:
A freeform optical element is introduced as an intermediary component between the standard rectangular projector and the spherical display surface. This element remaps the pixel distribution from a rectangular frustum to a spherical pattern, enabling efficient pixel utilization without modifying the projector itself. The optical element acts as a mediator that transforms the incompatible rectangular projection into a compatible spherical display format.
2Adaptability or versatility
If fish-eye lenses are used to adjust the rectangular projection frustum, then some pixel distribution adjustment is enabled, but tolerance for local pixel distribution tuning is limited and projection quality deteriorates
Solution Approach 1:
The patent employs a freeform optical element with specifically designed surface parameters that enable precise control over ray mapping. Unlike conventional fish-eye lenses with fixed parameters, the freeform surface allows for optimized parameter selection to achieve exact pixel distribution targets while maintaining high projection quality and minimizing aberrations.
3Adaptability or versatility
If anamorphic lenses are used to adjust the rectangular projection frustum, then aspect ratio changes are possible, but tolerance for pixel distribution tuning is limited and projection quality deteriorates
Solution Approach 1:
The freeform optical element enables local quality optimization by allowing different regions of the optical surface to have different mapping properties. This permits precise control over pixel distribution in specific areas of the projection, enabling both aspect ratio adjustment and localized pixel density optimization while maintaining high overall projection quality.
4Productivity
If multiple projectors are used to achieve optimal visual performance, then pixel distribution can be optimized, but system complexity increases and maintenance costs increase
Solution Approach 1:
The patent combines the functions of multiple projectors into a single projector system by using a freeform optical element to achieve the pixel distribution optimization that would otherwise require multiple projectors. This merging approach maintains optimal visual performance while reducing system complexity and eliminating the need for multiple projector units.
5Adaptability or versatility
If conventional lens systems are used for remapping, then pixel location adjustment is possible, but chromatic dispersion and aberrations increase
Solution Approach 1:
The patent replaces conventional refractive lens systems with a reflective freeform optical element. This substitution eliminates chromatic dispersion caused by refraction while maintaining the ability to adjust pixel locations through carefully designed reflective surface geometry. The reflective approach avoids the harmful chromatic effects inherent in refractive systems.
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 solution enables improved visual performance by optimizing pixel distribution, reducing the need for multiple projectors, lowering maintenance costs, and enhancing luminance and dynamic range, while minimizing chromatic dispersion and aberrations, thus addressing the inefficiencies of existing systems.
Implementation Method 1
The optical device may include at least a refractive element and a reflective element positioned in optical subsequence
Implementation Method 2
The optical device may include at least a refractive element and a reflective element positioned in optical subsequence
Data Source
AI summary
An apparatus and method for optically remapping projected pixels to maximize the utilization and to optimize the distribution of remapped projection pixels to achieve optimal visual performance (generally uniform resolution and luminance). A device interposed between a projector and an imaging surface for optically remapping projected pixel locations with minimal aberration. When this device is interposed between a projector and an imaging surface, it changes the terminal location of each focused pixel such that it maximally coincides with the imaging surface, which is often a surface of complex curvature and very different from the native focal surface of the projector. One implementation of the technology includes a device that uses multiple optical surfaces.