Light-selective prism, projection display apparatus using the same, and method of manufacturing light-selective prism

• US 6,411,449 B1
• Filed: 04/01/1999
• Issued: 06/25/2002
• Est. Priority Date: 04/08/1998
• Status: Expired due to Term

• Current Assignee: Seiko Epson Corporation (Seiko Group)
• Original Assignee: Seiko Epson Corporation (Seiko Group)
• Inventors: Hashizume, Toshiaki, Murata, Masami
• Primary Examiner(s): Shafer, Ricky D.
• Application Number:
  US09/285,003
• Time in Patent Office: 1,181 Days
• Field of Search: 359/634, 359/831, 359/833, 359/834, 359/900, 451/28, 451/41
• US Class Current: 359/831
• CPC Class Codes: G02B 27/1046 for use with transmissive spatial light modulators
• CPC Class Codes: G02B 27/1073 characterized by manufacturing or alignment methods
• CPC Class Codes: G02B 27/145 having sequential partially reflecting surfaces
• CPC Class Codes: G02B 27/149 using crossed beamsplitting surfaces, e.g. cross-dichroic cubes or X-cubes
• CPC Class Codes: G02B 5/04 Prisms
• CPC Class Codes: G03B 21/14 Details
• CPC Class Codes: G03B 33/12 using beam-splitting or beam-combining systems, e.g. dichroic mirrors
• CPC Class Codes: Y10S 359/90 Methods

Abstract

A red-reflecting film and a blue-reflecting film are formed in a substantially X shape on joint surfaces defined by the respective side faces of four columnar prisms or right-angle prisms. The red-reflecting film is continuously formed without separating at an intersection of the two reflecting films. The blue-reflecting film is, on the other hand, divided into two pieces by the red-reflecting film and an adhesive. It is preferable that that four columnar prisms are obtained from one block of sheet glass. This arrangement ensures an improvement in properties of a resulting light-selective prism.

Claims

1. A method of manufacturing a light-selective prism by joining four columnar prisms together on respective side faces thereof, the method comprising the steps of:

(A) preparing two pairs of prisms by;

i) providing two sets of two columnar prisms each having two joint side faces, wherein each set of two columnar prisms is a combination of a relatively long columnar prism and a relatively short columnar prism, and each pair of prisms are prepared in such a manner that one side face of the relatively long columnar prism, which is in contact with and glued to the relatively short columnar prism, has exposed portions on both longitudinal ends of the side face,

ii) forming a first light-selective film on one of four joint side faces of the two columnar prisms of each set, and

iii) gluing each set of two columnar prisms together across the first light-selective film;

(B) evenly polishing joint faces of the two pairs of prisms across which the two pairs of prisms are to be joined together;

(C) forming a second light-selective film over the even joint face of a selected one of the two pairs of prisms, the second light-selective film being continuous across a joint of the two columnar prisms in the selected pair; and

(D) joining the two pairs of prisms together in such a manner that the exposed portions of each pair of prisms are in contact with a predetermined common reference surface so as to obtain a prism assembly.

2. A method in accordance with claim 1, the method further comprising the step of:

cutting the light-selective prism out of the prism assembly obtained in the step (D).

3. A method in accordance with claim 1, wherein the step (B) includes the step of polishing at least one of the joint faces on which the second light-selective film is to be formed in the step (C), to a curved surface.

4. A method in accordance with claim 1, wherein at least the joint side faces of the two columnar prisms of each pair of prisms, are polished.

5. A method in accordance with claim 4, the method further comprising the step of:

polishing an outer face of the prism assembly obtained in the step (D).

6. A method in accordance with claim 4, the method further comprising the step of:

cutting a small prism out of the prism assembly obtained in the step (D).

7. A method in accordance with claim 6, the method further comprising the step of:

polishing an outer face of the small prism.

8. A method in accordance with claim 4, wherein the step (B) includes the step of polishing at least one of the joint faces on which the second light-selective film is to be formed in the step (C), to a curved surface.