Freeform mirror for illumination system of color-sequential LCOS pico projector

Abstract

An efficient and uniform illumination system with a freeform mirror for a color-sequential LCOS pico projector based on LED is proposed in this paper. The novel homogenizer is composed of a micro lens array and a freeform mirror. A freeform mirror with XY polynomial profile is adopted for the reshaping of light pattern, the correction of keystone distortion and the folding mirror for the reduction of volume. Typically, the design of micro lens array, the aspect ratio of the lenslet is corresponding with that of the panel. However, the crosstalk phenomenon occurs due to each lenslet with different collecting angle in horizontal and vertical direction, especially when the aspect ratio of the panel in our study is 16:9. The crosstalk phenomenon not only reduces efficiency but also generates stray light on the panel. Therefore, we use a micro lens array with square lenslet to eliminate it. Subsequently, the square light pattern on the panel needs to be reshaped to fit the aspect ratio of the panel. A cylindrical mirror with a fixed power is used to compress the light pattern first. However, for the requirement of different focal distances from the cylindrical mirror to the panel on entire surface, it generates severe keystone distortion. A freeform mirror with progressive power variation is employed for the correction of keystone distortion with high overfilled efficiency and the reshaping of the light pattern fitting the ratio of the panel. In the results of optical simulation, JBMA uniformity on the panel is 98 % and the coupling efficiency from LED to the plane of the panel is 85 %. Furthermore, the alignment tolerance of the freeform mirror has also been discussed. Finally, the freeform mirror is fabricated by ultra-precision diamond milling process. The form accuracy and surface roughness of the freeform mirror are less than 0.5 um and 5 nm, respectively.