Arbitrary surface optical element and method of making the same

• US 7,324,734 B2
• Filed: 09/20/2006
• Issued: 01/29/2008
• Est. Priority Date: 09/23/2005
• Status: Expired due to Fees

• Current Assignee: N-Lighten Technologies
• Original Assignee: N-Lighten Technologies
• Inventors: Chuang, Charles Chia-ming, Burnett, William Robert, Poppell, David Daniel, Davies, Kathleen Hannon, Guo, Qing, Frey, Paul D.
• Primary Examiner(s): Pak; Sung
• Assistant Examiner(s): ROJAS, OMAR R
• Application Number:
  US11/533,763
• Publication Number:
  US 20070081786A1
• Time in Patent Office: 496 Days
• Field of Search: None
• US Class Current: 385/147
• CPC Class Codes: B29C 45/1418 the inserts being deformed or preformed, e.g. by the injection pressure
• CPC Class Codes: B29C 45/14778 the article consisting of a material with particular properties, e.g. porous, brittle
• CPC Class Codes: B29D 11/00865 Applying coatings; tinting; colouring printing, marking or copying processes B41M; identification in general G09F3/00; producing decorative effects in general B44C; positioning or marking of lenses B24B13/0055
• CPC Class Codes: G02B 5/10 with curved faces
• CPC Class Codes: G02B 7/008 with means for compensating for changes in temperature or for controlling the temperature; thermal stabilisation
• CPC Class Codes: G03B 21/28 Reflectors in projection beam in illumination beam G03B21/2066
• CPC Class Codes: H04N 9/3141 Constructional details thereof details not peculiar to the presence of an electronic spatial light modulator G03B21/14

Abstract

An arbitrary surface optical element, such as a mirror for use in a rear projection television, includes a non-optical portion and an optical portion. The non-optical portion circumscribes the optical portion and has a thickness greater than the optical portion. Accordingly, the two portions cool at approximately the same rate, thereby minimizing warpage from differential cooling.

Claims

1. An optical element, comprising:

a part having a non-optical portion and a optical portion, the non-optical portion circumscribing edges of the optical portion and having a thermal mass greater than the optical portion such that the cooling rates of the non-optical and optical portions during joint manufacture are about equal to counteract edge effect experienced by the combined portions during the joint manufacture; and

a thin film layer on at least the optical portion, the thin film including one or more of a polarizing layer, a photochromic layer, a melanin layer, a mirror layer, a color filter, or an infrared filter.

2. The optical element of claim 1, wherein the part is formed of a thermoplastic material and wherein the element further comprises a protective film between a metallic layer and the part.

3. The optical element of claim 2, wherein the film is adhered to the part with a pressure sensitive or thermo set adhesive that has a higher melt temperature than either the film or a base material of the part.

4. The optical element of claim 1, wherein the part is formed on a mold that forms a base of the optical element.

5. The optical element of claim 1, wherein the non-optical portion includes at least one rib.

6. The optical element of claim 1, wherein the non-optical portion extends outward from the optical portion with a dimension that is at least about twice the thickness of the optical portion.

7. The optical element of claim 1, wherein the thin film is a polarizing layer.

8. The optical element of claim 1, wherein the thin film is a photochromic layer.

9. The optical element of claim 1, wherein the thin film is a melanin layer.

10. The optical element of claim 1, wherein the thin film is a mirror layer.

11. The optical element of claim 1, wherein the thin film is a color filter.

12. The optical element of claim 1, wherein the thin film is an infrared filter.

13. A display, comprising:

a screen;

an optical engine that projects images; and

a first mirror positioned to reflect the images from the optical engine onto the screen, the mirror having a non-optical portion and an optical portion, the non-optical portion circumscribing edges of the optical portion and having a thermal mass greater than the optical portion such that the cooling rates of the non-optical and optical portions during joint manufacture are about equal to counteract edge effect experienced by the combined portions during the joint manufacture.

14. The display of claim 13, wherein the optical portion includes a thin film layer disposed thereon.

15. The display of claim 14, wherein the thin film includes one or more of a polarizing layer, a photochromic layer, a melanin layer, a mirror layer, a color filter, or an infrared filter.

16. The display of claim 13, wherein the part is formed of a thermoplastic material and wherein the element further comprises a protective film between a-metallic layer and the part.

17. The display of claim 16, wherein the film is adhered to the part with a pressure sensitive or thermo set adhesive that has a higher melt temperature than either the film or a base material of the part.

18. The display of claim 13, wherein the part is formed on a mold that forms a base of the optical element.

19. The display of claim 13, wherein the non-optical portion includes at least one rib.

20. The display of claim 13, wherein the non-optical portion extends outward from the optical portion with a dimension that is at least about twice the thickness of the optical portion.

21. The display of claim 13, further comprising a second mirror positioned to reflect the images from the light engine onto the first mirror.