Reflector with de-coupling interface layer

• US 7,507,002 B2
• Filed: 07/01/2005
• Issued: 03/24/2009
• Est. Priority Date: 07/01/2005
• Status: Expired due to Fees

• Current Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Original Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Inventors: Ulmer, Kurt M., Wu, Kuohua
• Primary Examiner(s): O'Shea; Sandra L
• Assistant Examiner(s): CARTER, WILLIAM JOSEPH
• Application Number:
  US11/173,320
• Publication Number:
  US 20070002569A1
• Time in Patent Office: 1,362 Days
• Field of Search: 362/296, 362/307, 362/341, 362/343, 362/344, 362/254
• US Class Current: 362/307
• CPC Class Codes: C23C 28/00 Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
• CPC Class Codes: F21V 7/24 characterised by the material
• CPC Class Codes: F21V 7/28 characterised by coatings
• CPC Class Codes: H01J 61/025 Associated optical elements
• CPC Class Codes: H01J 61/35 provided with coatings on the walls thereof; Selection of materials for the coatings using coloured coatings H01J61/40; using luminescent coatings H01J61/42

Abstract

A method for forming a reflector includes depositing a decoupling material on an ultraviolet light and infra-red light absorption layer that is supported by a substrate which is spun.

Claims

1. A reflector comprising:

a substrate comprising a first surface roughness;

an ultraviolet light and infra-red light absorption layer on the substrate;

a de-coupling layer on the absorption layer, wherein the de-coupling layer is selected from a group of materials consisting of;

spun-on glass, methylsiloxane silicate, sodium silicate, tetraethylorthosilicate (TEOS) and sol-gel material; and

an optical coating on the de-coupling layer;

wherein said de-coupling layer comprises a surface adjacent said optical coating having a second roughness less than said first surface roughness.

2. The reflector of claim 1 wherein the subs irate comprises a metal.

3. The substrate of claim 1, wherein the substrate comprises aluminum.

4. The reflector of claim 1, wherein the de-coupling layer is spin coated on the absorption layer.

5. The reflector of claim 1, wherein the decoupling layer has a substantially uniform thickness across the absorption layer.

6. The reflector of claim 1, wherein the de-coupling layer has an outer surface having a smoothness of at least about 20 nanometers.

7. The reflector of claim 1, wherein the de-coupling layer has an extinction coefficient near zero.

8. The reflector of claim 1, wherein the de-coupling layer has a refractive index of between about 1.35 and about 1.55.

9. The reflector of claim 1, wherein the de-coupling layer has a thickness of between 2 microns and 10 microns.

10. The reflector of claim 1, wherein the absorption layer has a surface roughness about 1 micrometer

11. The reflector of claim 1, wherein the absorption layer is selected from a group of materials consisting of:

carbon-based pigment, black anodized aluminum.

12. The reflector of claim 1, wherein the ultraviolet light and infrared light absorption layer is in contact with the substrate and is in contact with the de-coupling layer.

13. The reflector of claim 1, wherein the ultraviolet light and infrared light absorption layer is between the substrate and the de-coupling layer.

14. The reflector of claim 1, wherein the ultraviolet light and infrared light absorption layer has a first surface roughness and wherein the de-coupling layer has a surface adjacent the optical coating having a second surface roughness less than the first surface roughness.

15. A lamp comprising:

a reflector including;

a substrate comprising a first surface roughness;

an ultraviolet and infrared light absorption on the substrate;

a de-coupling layer on the absorption layer, wherein the de-coupling layer is selected from a group of materials consisting of;

spun-on glass, methylsiloxane silicate, sodium silicate, TEOS and sol-gel material; and

an optical coating on the de-coupling layer, wherein said de-coupling layer comprises a surface adjacent said optical coating having a second surface roughness less than said first surface roughness; and

a burner proximate the reflector.

16. The lamp of claim 15, wherein the burner comprises a high press arc burner.

17. A projector comprising:

a lamp including;

an ellipsoidal substrate comprising a first surface roughness;

an ultraviolet light and infra-red light absorption layer on the substrate;

a de-coupling layer on the absorption layer, wherein the de-coupling layer is selected from a group of materials consisting of;

spun-on glass, methylsiloxane silicate, sodium silicate, TEOS and sol-gel material; and

an optical coating on the dc-coupling layer;

wherein said de-coupling layer comprises a surface adjacent said optical coating having a second surface roughness less than said first surface roughness;

a burner proximate the optical coating;

a light modulator; and

a color wheel through which light from the lamp passes before impinging the light modulator.

18. A reflector comprising:

a substrate comprising a first surface roughness;

means for absorbing ultraviolet and infra-red light disposed on said substrate;

means for reflecting visible light disposed on said absorbing means; and

means for interfacing between the absorbing means and the reflecting means and for providing a smooth surface against the reflecting means wherein the means for interfacing comprises a material selected from a group of materials consisting of;

spun-on glass, methylsiloxane silicate, sodium silicate, TEOS and sol-gel material;

wherein said interfacing means comprises a surface adjacent said reflecting means having a second surface roughness less than said first surface roughness.