Design and evaluation of laser spot illuminator for a laser projection engine design

Abstract

An easily implementable illumination optical element enabling collection and redirection of multiple precollimated laser beams to be used as a laser spot illuminator (LSI) is proposed. Unlike the lenses, this element is free from any aberration and focusing/defocusing effects which may arise due to curved surfaces. The nonfocusing nature of beams reduces risk of the thermal instability at the target spot if compared with focused beam, especially for high brightness applications where multiple laser beams are used. Further, the illuminating spot is more uniform and pupil filling is higher which can help in the reduction of speckle contrast for imaging applications. In this research, we present two designs of LSI named biprism and sleek design, suitable for conventional grinding-polishing and molding methods of fabrication, respectively. It is shown that the proposed spot illuminator is suitable for conversion of lamp/LED-based projection engine design into a laser projector engine without any modification in its relay and imaging optics. Display performance parameters such as efficiency and uniformity across the modulator plane are reported and found acceptable for the projection engine designs using light tunnels as well as lenslet arrays for homogenization. Further, a prototype of a biprism laser illuminator for 2×4 laser arrays has been fabricated and evaluated to demonstrate its manufacturability.