Projection System Optical Element Refraction Reflection

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Solution Overview

Problem

The existing projection systems face challenges in shortening the projection distance while maintaining image quality and resolution, particularly due to difficulties in designing the optical systems with reflection surfaces and transmissive surfaces effectively.

Innovation Solution

The projection system incorporates a first optical system and a second optical system with an optical element having a reflection surface, a first transmissive surface, and a second transmissive surface, along with a reflector, which are strategically positioned to refract and direct light fluxes, allowing for a shorter projection distance without compromising image quality by suppressing aberrations and inclination of intermediate images.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If a conventional projection system with reflection mirror and refractive optical system is used, then the system can form projection images, but the projection distance cannot be sufficiently shortened due to design difficulties

Engineering Contradiction:
Improveprojection distanceVSAvoidoptical system design complexity
Core Design Contradiction:
Length of moving objectVSDevice complexity

Solution Approach 1:

The patent combines the reflection surface and transmissive surfaces into a single integrated optical element. This optical element has a reflection surface facing the reduction-side image formation plane and a transmissive surface facing the enlargement-side image formation plane, allowing it to perform both reflection and refraction functions simultaneously. This merging resolves the contradiction by simplifying the optical system structure while enabling shorter projection distance.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The optical element serves multiple functions: it acts as both a reflective surface for forming intermediate images and a transmissive surface for final image projection. Additionally, the reflector and optical element work together to control light flux in multiple directions. This multi-functionality reduces the number of separate components needed, thereby shortening the projection distance without excessive complexity.

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Length of moving object

If the projection distance is shortened, then the system becomes more compact, but image quality deteriorates due to increased aberrations and intermediate image inclination

Engineering Contradiction:
Improveprojection distanceVSAvoidimage quality
Core Design Contradiction:
Length of moving objectVSManufacturing precision

Solution Approach 1:

The patent applies different surface characteristics to different parts of the optical element. The reflection surface has specific curvature properties optimized for intermediate image formation, while the transmissive surface has different curvature properties optimized for final image projection. This local optimization of surface qualities allows the system to maintain high image quality even with shortened projection distance by compensating for aberrations locally.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent optimizes specific parameters including the curvature radii of the reflection and transmissive surfaces, the relative positioning between the optical element and reflector, and the refractive indices of optical materials. By carefully adjusting these parameters, the system achieves short projection distance while maintaining image quality through aberration suppression.

Inventive Principle:
Principle #35Parameter changes

3Illumination intensity

If a reflection mirror is used in the projection system, then the optical path can be controlled, but light loss occurs at the periphery and contrast reproduction ratio decreases

Engineering Contradiction:
Improvelight flux distributionVSAvoidlight loss
Core Design Contradiction:
Illumination intensityVSLoss of energy

Solution Approach 1:

The patent replaces the conventional reflection mirror with an optical element that uses refraction in addition to reflection. The transmissive surface of the optical element refracts light flux to reach the enlargement-side image formation plane, providing an alternative path that reduces peripheral light loss. This substitution of pure reflection with a combination of reflection and refraction mechanisms improves light utilization efficiency and contrast reproduction.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

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

This configuration enables a shorter focal length and improved resolution, reducing light loss at the periphery and maintaining high contrast reproduction ratios, thus enhancing the projection system's performance and efficiency.

Implementation Method 1

an optical element (33) having a reflection surface (41), a first transmissive surface (42), and a second transmissive surface (43)

Methodology Applied
Scientific EffectRefraction: Refraction

Implementation Method 2

The intermediate image (35) is formed between the first optical system (31) and the reflection surface (41) of the optical element (33)

Methodology Applied
Scientific EffectReflection: Reflection

Data Source

PatentUS11892764B2Projection system and projector
Publication Date: 2024.02.06 SEIKO EPSON CORP
  • US11892764B2 patent drawing
  • US11892764B2 patent drawing
  • US11892764B2 patent drawing

AI summary

A projection system includes a first optical system and a second optical system including an optical element and a reflector and disposed at the enlargement side of the first optical system. The optical element has a reflection surface, a first transmissive surface disposed at the enlargement side of the reflection surface, and a second transmissive surface disposed at the enlargement side of the first transmissive surface. The reflector is disposed at the enlargement side of the reflection surface and at the reduction side of the first transmissive surface. The reflector is disposed between the optical element and the first optical system in the direction along a first optical axis of the first optical system.