CN114879433B

CN114879433B - Projection system and preparation method thereof

Info

Publication number: CN114879433B
Application number: CN202110160069.0A
Authority: CN
Inventors: 孙永强; 王志超; 郎海涛; 李明亮; 朱旭彪
Original assignee: Ningbo Sunny Automotive Optech Co Ltd
Current assignee: Ningbo Sunny Automotive Optech Co Ltd
Priority date: 2021-02-05
Filing date: 2021-02-05
Publication date: 2024-07-23
Anticipated expiration: 2041-02-05
Also published as: CN114879433A

Abstract

The application provides a projection system and a preparation method thereof, wherein the projection system comprises: the device comprises a light source module, a special-shaped projection surface and a shaping module. The light source module is used for generating emitted light. The shaping module is arranged on the light path of the emitted light and is positioned between the light source module and the special-shaped projection surface, and the shaping module comprises a plurality of sub-lenses, wherein the projection shape of the sub-lenses in the light path direction is identical to or corresponding to the shape of the special-shaped projection surface, so that the projection of the plurality of sub-lenses in the light path direction is identical to the shape of the special-shaped projection surface after being mutually overlapped. The projection system provided by the application can realize the projection of the projection system on the special-shaped projection surface while not increasing the difficulty of the original preparation process and ensuring the light and thin property of the projection system. Further, a decrease in the working efficiency of the projection system caused by increasing the number of optical elements or adjusting the working parameters of the original optical elements can also be avoided.

Description

Projection system and preparation method thereof

Technical Field

The present disclosure relates to optical devices, and particularly to a projection system and a method for manufacturing the same.

Background

The projection system is an optical system for imaging an object onto a projection surface after illumination, and the projection surface is usually a rectangular plane, and the shape of a spot including projection information projected by the projection system is also rectangular so as to fit the shape of the projection surface. However, in some application fields, the shape of the projection surface is not limited to rectangle, and in order to match the shape of the projection surface, a special-shaped diaphragm similar to the shape of the projection surface is usually added in the projection system by the conventional process; or the part of the illumination chip of the projection system, which is similar to the projection surface, is used for projection, so that the shape of the light spot projected by the projection system is matched with the shape of the projection surface, and the projection requirement of the special-shaped projection surface is met. However, changing the shape of the spot projected by the projection system by the above scheme may reduce the working efficiency of the projection system.

In practice, the shape of the spot projected by the projection system containing the projected information is defined by the shape of each subunit on the fly-eye lens. Specifically, the light spot projected by the projection system is the effect of the superposition of the emergent light of each subunit on the fly-eye lens on the projection surface. Therefore, if the shape of each subunit on the fly-eye lens is adjusted according to the actual shape of the projection surface, the light spot formed by overlapping the emergent light passing through each subunit on the projection surface can be matched with the shape of the projection surface.

Therefore, how to obtain a high-efficiency and low-cost projection system while meeting the projection requirements of the special-shaped projection surface is a problem to be solved by those skilled in the art.

Disclosure of Invention

The present application provides a projection system and method of manufacture that at least partially addresses at least one of the above-described shortcomings of the prior art.

According to one aspect of the present application there is provided a projection system comprising: a light source module for generating emitted light; a contoured projection surface, wherein the projection system further comprises: the shaping module is arranged on the light path of the emitted light and is positioned between the light source module and the special-shaped projection surface, and the shaping module comprises a plurality of sub lenses, wherein the projection shape of the sub lenses in the light path direction is identical to or corresponding to the shape of the special-shaped projection surface, so that the projection of the plurality of sub lenses in the light path direction is identical to the shape of the special-shaped projection surface after being mutually overlapped.

According to one embodiment of the application, the shape of the projection of the sub-lens on the optical path of the emitted light is at least one of a circle, a triangle, a quadrangle and a pentagon or any combination thereof.

According to one embodiment of the application, a plurality of said sub-lenses have the same shape, the same dimensions, the same refractive index of the material, the same thickness and the same curvature.

According to an embodiment of the present application, the arrangement of the plurality of sub-lenses includes any one or a combination of a circular arrangement, an annular arrangement, a triangular arrangement, and a pentagonal arrangement.

According to one embodiment of the present application, adjacent sub-lenses have the same pitch therebetween.

According to one embodiment of the present application, the shaping module further includes a substrate, and the substrate is symmetrically provided with a sub-lens array formed by a plurality of sub-lenses on both sides or a sub-lens array formed by a plurality of sub-lenses on either side of the substrate.

According to one embodiment of the present application, a corresponding side length H of a spot area formed on the shaped projection surface by the light emitted from the sub-lens and a side length d of the sub-lens corresponding to the side length H of the shaped projection surface satisfy:

tansin^-1(d/2nL)＝H/2f，

Wherein n is the refractive index of the sub-lens, L is the thickness of the sub-lens, and f is the focal length of the optical module between the sub-lens and the shaped projection surface.

According to an embodiment of the present application, in the case where the shape of the shaped projection surface is a parallelogram, the shape of the projection of the sub-lens in the optical path direction of the emitted light is the same as the shape of the shaped projection surface, and the shape of the projection of the sub-lens is a parallelogram.

According to an embodiment of the present application, in a case where the shape of the shaped projection surface is hexagonal, the shape of the projection of the sub-lens in the optical path direction of the emitted light corresponds to the shape of the shaped projection surface, and the shape of the projection of the sub-lens is trapezoidal. According to one embodiment of the application, the sub-lenses are made of at least one of cycloolefin copolymer COP plastic or glass.

According to one embodiment of the application, the shaping module is made of at least one of cycloolefin copolymer COP plastic or glass.

According to one embodiment of the application, the sub-lenses are prepared by at least one of an injection molding process or a thermal molding process.

According to one embodiment of the application, the shaping module is prepared by at least one of an injection molding process or a hot molding process.

According to one embodiment of the present application, the light source module includes any one or a combination of RGB monochromatic light sources.

According to an embodiment of the present application, the light source module includes at least one of an LED light source and a laser light source.

According to one embodiment of the application, the projection system further comprises a dimming module comprising at least one collimating lens and at least one color filter.

According to one embodiment of the application, the projection system further comprises a dimming module, the dimming module further comprising at least one corrective lens.

According to one embodiment of the application, the projection system further comprises a turning module comprising at least one relay lens, at least one mirror and at least one right angle prism.

According to one embodiment of the application, the projection system further comprises an image generation module comprising one or more of a DMD module, a MEMS module, and an LCOS module.

According to one embodiment of the application, the projection system further comprises a folding module and an image generation module, wherein the image generation module is used for receiving the special-shaped projection transmitted by the folding module and projected by the shaping module and generating an image with the same shape as the special-shaped projection surface.

According to another aspect of the present application there is provided a method of manufacturing a projection system comprising: a shaping module is arranged on a light path of the emitted light of the light source module, wherein the shaping module is composed of a plurality of sub lenses; and setting a special-shaped projection surface on the light path, wherein the projection shape of the sub-lenses in the light path direction is the same as or corresponding to the shape of the special-shaped projection surface, so that the projections of the plurality of sub-lenses in the light path direction are overlapped with each other and then are the same as the shape of the special-shaped projection surface.

According to one embodiment of the present application, the shaping module is composed of a plurality of sub-lenses including: the projection shape of the sub-lens on the light path of the emitted light is set to at least one of a circle, a triangle, a quadrangle, and a pentagon, or any combination thereof.

According to one embodiment of the present application, the shaping module is composed of a plurality of sub-lenses including: a plurality of the sub-lenses are arranged in the same shape, the same size, the same material refractive index, the same thickness, and the same curvature to form the shaping module.

According to one embodiment of the present application, the shaping module is composed of a plurality of sub-lenses including: and arranging a plurality of the sub-lenses in any one or combination of circular arrangement, annular arrangement, triangular arrangement and pentagonal arrangement to form the shaping module.

According to one embodiment of the present application, the shaping module is composed of a plurality of sub-lenses including: and setting the spacing between adjacent sub-lenses to be the same so as to form the shaping module.

According to one embodiment of the application, the shaping module further comprises a substrate, wherein the shaping module is composed of a plurality of sub-lenses comprising: symmetrically arranging sub-lens arrays comprising a plurality of sub-lenses on two sides of the substrate to form the shaping module; or a sub-lens array comprising a plurality of sub-lenses is arranged on any side of the substrate to form the shaping module.

According to an embodiment of the present application, setting the shape of the projection of the sub-lens in the optical path direction to be the same as or corresponding to the shape of the shaped projection surface includes: the corresponding side length H of the spot area formed by the light emitted by the sub-lens on the special-shaped projection surface and the side length d of the sub-lens corresponding to the side length H of the special-shaped projection surface meet the following conditions:

tansin^-1(d/2nL)＝H/2f，

According to an embodiment of the present application, setting the shape of the projection of the sub-lens in the optical path direction to be the same as or corresponding to the shape of the shaped projection surface includes: in the case where the shape of the shaped projection surface is a parallelogram, the shape of the projection of the sub-lens in the optical path direction of the emitted light is set to be the same as the shape of the shaped projection surface, and the shape of the projection of the sub-lens is a parallelogram.

According to an embodiment of the present application, setting the shape of the projection of the sub-lens in the optical path direction to be the same as or corresponding to the shape of the shaped projection surface includes: when the shape of the irregular projection surface is hexagonal, the shape of the projection of the sub-lens in the optical path direction of the emitted light is set to correspond to the shape of the irregular projection surface, and the shape of the projection of the sub-lens is trapezoidal.

According to one embodiment of the application, forming the shaping module using a plurality of identical sub-lenses comprises: the sub-lenses are prepared from at least one of a cyclic olefin copolymer, COP, plastic or glass to form the shaping module.

According to one embodiment of the application, forming the shaping module using a plurality of identical sub-lenses comprises: the shaping module is made of at least one of a cycloolefin copolymer COP plastic or glass.

According to one embodiment of the application, forming the shaping module using a plurality of identical sub-lenses comprises: the sub-lenses are prepared by at least one of an injection molding process or a thermal molding process to form the shaping module.

According to one embodiment of the application, forming the shaping module using a plurality of identical sub-lenses comprises: the shaping module is prepared by at least one of an injection molding process or a hot molding process.

According to one embodiment of the application, the method comprises: any one or a combination of RGB single-color light sources is arranged in the light source module.

According to one embodiment of the application, the method comprises: at least one of an LED light source and a laser light source is provided in the light source module.

According to one embodiment of the application, the method comprises: and setting the dimming module on the light-emitting path of the light source module, wherein at least one collimating lens and at least one color filter are arranged in the dimming module.

According to one embodiment of the application, the method further comprises: and setting the dimming module on the light-emitting path of the light source module, wherein at least one correcting lens is arranged in the dimming module.

According to one embodiment of the application, the method comprises: and setting a turning module on the light emitting path of the dimming module, wherein at least one relay lens, at least one reflecting mirror and at least one right-angle prism are arranged in the turning module.

According to one embodiment of the application, the method further comprises: an image generation module is arranged in the projection system, and the image generation module comprises one or more of a DMD module, a MEMS module and an LCOS module.

According to one embodiment of the application, the method further comprises: the projection system is provided with a deflection module and an image generation module, wherein the image generation module is used for receiving the special-shaped projection transmitted by the deflection module and projected by the shaping module and generating an image with the same shape as the special-shaped projection surface.

According to at least one scheme of the projection system and the preparation method thereof provided by the application, the shape of each sub-lens on the fly-eye lens is adjusted, so that the light spots formed by overlapping the light emitted by each sub-lens on the projection surface are the same or similar to the shape of the projection surface, and the projection requirements of various special-shaped projection scenes are further met.

The preparation method of the projection system provided by the application can realize the projection of the projection system on the special-shaped projection surface while not increasing the difficulty of the original preparation process and ensuring the light and thin property of the projection system. Further, a decrease in the working efficiency of the projection system caused by increasing the number of optical elements or adjusting the working parameters of the original optical elements can also be avoided.

In addition, the projection system provided by the application has the characteristics of simple structure, low cost and easiness in quantitative production.

Drawings

Other features, objects and advantages of the present application will become more apparent upon reading of the detailed description of non-limiting embodiments, made with reference to the accompanying drawings in which:

FIG. 1 is a schematic diagram of a projection system according to an exemplary embodiment of the present application;

FIG. 2 is a schematic diagram of a fly-eye lens configuration with parallelogram-shaped sub-lenses in a projection system according to an exemplary embodiment of the application;

FIG. 3 is an enlarged view of area A of the fly's eye lens of FIG. 2;

FIG. 4 is a plot of the effect of a spot on a projection surface for a projection system employing the fly-eye lens of FIG. 2;

FIG. 5 is a schematic diagram of a fly-eye lens configuration with trapezoidal shaped sub-lenses in a projection system according to an exemplary embodiment of the application;

FIG. 6 is an enlarged view of region B of the fly's eye lens of FIG. 5;

FIG. 7 is a plot of the effect of a spot on a projection surface for a projection system employing the fly-eye lens of FIG. 5;

FIG. 8 is a flowchart of a method of manufacturing a projection system according to an exemplary embodiment of the present application;

Fig. 9 is a schematic diagram of the morphology of triangular sub-lenses in a fly-eye lens according to an exemplary embodiment of the application;

FIG. 10 is a graph of the effect of achieving parallelogram spots on a projection surface including a fly-eye lens employing the sub-lenses of FIG. 9;

FIG. 11 is a diagram of a hexagonal spot effect achieved on a projection surface including a fly-eye lens employing the sub-lenses of FIG. 9;

FIG. 12 is a graph of the effect of pentagonal spots on a projection surface including a fly-eye lens employing the sub-lenses of FIG. 9;

FIG. 13 is a schematic diagram of sub-lens distribution in a circular arrangement according to an exemplary embodiment of the present application; and

Fig. 14 is a schematic diagram of sub-lens distribution in a rectangular arrangement according to an exemplary embodiment of the present application.

Detailed Description

For a better understanding of the application, various aspects of the application will be described in more detail with reference to the accompanying drawings. It should be understood that the detailed description is merely illustrative of exemplary embodiments of the application and is not intended to limit the scope of the application in any way. Like reference numerals refer to like elements throughout the specification. The expression "and/or" includes any and all combinations of one or more of the associated listed items.

It should be noted that in the present specification, the expressions of first, second, third, etc. are only used to distinguish one feature from another feature, and do not represent any limitation on the feature. Thus, for example, a first light emitting unit discussed below may also be referred to as a second light emitting unit without departing from the teachings of the present application. And vice versa.

Note that in this specification, the expression of shape implies features of cover type, size, height, style, and the like. Accordingly, a "shape" in the present application may refer to a "shape" as understood by those skilled in the art of this patent without departing from the teachings of the present application.

In the drawings, the thickness, size, and shape of the components have been slightly adjusted for convenience of description. The figures are merely examples and are not drawn to scale. As used herein, the terms "about," "approximately," and the like are used as terms of a table approximation, not as terms of a table degree, and are intended to account for inherent deviations in measured or calculated values that will be recognized by one of ordinary skill in the art.

It will be further understood that terms such as "comprises," "comprising," "includes," "including," "having," "containing," "includes" and/or "including" are open-ended, rather than closed-ended, terms that specify the presence of the stated features, elements, and/or components, but do not preclude the presence or addition of one or more other features, elements, components, and/or groups thereof. Furthermore, when a statement such as "at least one of the following" appears after a list of features listed, it modifies the entire list of features rather than just modifying the individual elements in the list. Furthermore, when describing embodiments of the application, use of "may" means "one or more embodiments of the application. Also, the term "exemplary" is intended to refer to an example or illustration.

Unless otherwise defined, all terms (including engineering and technical terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present application pertains. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

In addition, the embodiments of the present application and the features of the embodiments may be combined with each other without collision. In addition, unless explicitly defined or contradicted by context, the particular steps included in the methods described herein need not be limited to the order described, but may be performed in any order or in parallel. The present application will be described in detail below with reference to the accompanying drawings in conjunction with embodiments.

Fig. 1 is a schematic diagram of a structure of a projection system according to an exemplary embodiment of the present application.

As shown in fig. 1, the present application provides a projection system including: the device comprises a light source module 1, a shaping module 3, a projection module 6 and a special-shaped projection surface 7. The light source module 1 is for generating emitted light. The projection module 6 comprises a projection lens. The shaping module 3 is arranged on the light path of the emitted light generated by the light source module 1 and is located between the light source module 1 and the profiled projection surface 7. The shaping module 3 includes a plurality of sub-lenses 31, and the projection of the sub-lenses 31 in the optical path direction has the same or corresponding shape as the shape of the special-shaped projection surface 7, so that the projections of the plurality of sub-lenses 31 in the optical path direction are overlapped with each other and then have the same shape as the special-shaped projection surface 7.

The light source module 1 may include a first light emitting unit 11, a second light emitting unit 12, and a third light emitting unit 13. The first, second and third light emitting units 11, 12 and 13 provide monochromatic light sources of three colors of red, green and blue (RGB), respectively, for example, the first light emitting unit 11 may emit red light, the second light emitting unit 12 may emit green light, and the third light emitting unit 13 may emit blue light. Of course, the positions of the three light emitting units can be replaced according to the requirement, and the application is not limited thereto. Further, the light source module 1 adjusts the proportions of the emitted light of the first light emitting unit 11, the second light emitting unit 12 and the third light emitting unit 13 according to the color of the emitted light required by the projection system, so that the color of the emitted light of the light source module 1 meets the requirement of the projection system.

In some embodiments, the three light emitting units of the light source module 1 may be LED (LIGHT EMITTING Diode) light sources or LD (Laser Diode) light sources. Although only two types of light sources are exemplified here, the specific embodiment of the light emitting unit 11 of the present embodiment is not limited thereto.

In the embodiment of the present application, three light emitting units of the light source module 1 are LED light sources. Since the emitted light of the LED light source has divergency, when the LED light source is used as the three light emitting units of the light source module 1, the dimming module 2 (the dimming module 2 will be described in detail later in the present application) needs to be provided to collimate the emitted light of the three light emitting units, respectively, so as to improve the directionality of the emitted light, so that the emitted light can be parallel as much as possible. If the directivities of the emitted lights of the three light emitting units of the light source module 1 are sufficiently high and sufficiently parallel to each other, the number of the collimator lenses used in the dimming module 2 may be appropriately reduced or the use of the dimming module 2 may be directly omitted in the embodiment of the present application.

Further, in one embodiment of the present application, the projection system further includes: a dimming module 2. The dimming module may be disposed on the light-emitting path of the light source module 1 and located between the light source module 1 and the shaping module 3, for collimating and turning the emitted light.

The dimming module 2 may include a first collimating unit 21, a second collimating unit 22, and a third collimating unit 23. The first collimating unit 21 is disposed on the light-emitting path of the first light-emitting unit 11, for collimating the emitted light of the first light-emitting unit 11. The second collimating unit 22 is disposed on the light-emitting path of the second light-emitting unit 12, and is used for collimating the emitted light of the second light-emitting unit 12. The third collimating unit 23 is disposed on the light-emitting path of the third light emitting unit 13 for collimating the emitted light of the third light emitting unit 13.

Further, the first collimating unit 21 may include a first collimating lens 211 and a second collimating lens 212. The first collimating lens 211 and the second collimating lens 212 are sequentially arranged on the light-emitting path of the first light-emitting unit 11. The side of the first collimating lens 211 remote from the first light emitting unit 11 is a mirror surface having a curvature. The first collimating lens 211 is for receiving the emitted light of the first light emitting unit 11 and performing preliminary collimation. Both sides of the second collimating lens 212 are mirror surfaces having curvature. The second collimating lens 212 is for receiving the emitted light passing through the first collimating lens 211 and secondarily collimating the emitted light. The emitted light is collimated by the first collimating lens 211 and the second collimating lens 212, and then has a predetermined directivity and parallelism.

In some embodiments, a color filter 213 may be disposed on the light-emitting path of the second collimating lens 212. The color filter 213 is selected according to the color of the emitted light of the light emitting unit corresponding to the collimating unit in which it is located, for example, when the emitted light of the first light emitting unit 11 is red, the color filter 213 having anti-red property will be selected. The color filter 213 having anti-red property is used to correct the emitted light passing through the second collimating lens 12, which is advantageous for enhancing the color effect of the emitted light. In addition, by changing the propagation path of the emitted light under the reflection of the color filter 213, the path length required for light propagation is satisfied without expanding the space, thereby having the effect of saving space, and in addition, the performance of the projection system can be improved.

In some embodiments, a second collimating unit 22 may be disposed on the light-emitting path of the first collimating unit 21. The second collimating unit 22 is configured to collimate the emitted light of the second light emitting unit 12. The second collimating unit 22 may include a third collimating lens 221 and a fourth collimating lens 222. The third collimating lens 221 and the fourth collimating lens 222 are sequentially arranged on the light-emitting path of the second light-emitting unit 12. The side of the third collimating lens 221 remote from the second light emitting unit 12 is a mirror surface having curvature. The third collimating lens 221 is for receiving the emitted light of the second light emitting unit 12 and performing preliminary collimation. Both sides of the fourth collimating lens 222 are mirror surfaces having curvature. The fourth collimating lens 222 is for receiving the emitted light passing through the third collimating lens 221 and secondarily collimating the emitted light. The emitted light is collimated by the third collimating lens 221 and the fourth collimating lens 222, and then has a predetermined directivity and parallelism.

In some embodiments, a color filter 223 may be disposed on the light-emitting path of the fourth collimating lens 222. The color filter 223 is selected according to the color of the emitted light of the light emitting unit corresponding to the collimating unit where it is located, for example, when the emitted light of the second light emitting unit 12 is green, a color filter having anti-green property will be selected. The color filter 223 having the anti-green property is used to correct the emitted light passing through the fourth collimating lens 222, which is advantageous in enhancing the color effect of the emitted light. In addition, the color filter 223 is also used to receive and transmit red-emitting light passing through the first collimating unit 21. The color filter 223 has a property of transmitting red light while having a property of reflecting green light. Of course, the performance of the color filter 223 is selected according to the requirements of the location thereof, and the present application is not limited thereto. In addition, by changing the propagation path of the emitted light under the reflection of the color filter 223, the path length required for light propagation is satisfied without expanding the space, so that the space saving effect is provided, and the performance of the projection system can be improved.

In some embodiments, a third collimating unit 23 may be disposed on the light-emitting path of the second collimating unit 22. The third collimating unit 23 is for collimating the emitted light of the third light emitting unit 13. The third collimating unit 23 may include a fifth collimating lens 231 and a sixth collimating lens 232. The fifth collimating lens 231 and the sixth collimating lens 232 are sequentially arranged on the light-emitting path of the third light-emitting unit 13. The side of the fifth collimating lens 231 remote from the third light emitting unit 13 is a mirror surface having curvature. The fifth collimating lens 231 is for receiving the emitted light of the third light emitting unit 13 and performing preliminary collimation. Both sides of the sixth collimating lens 232 are mirror surfaces having curvature. The sixth collimating lens 232 is for receiving the emitted light passing through the fifth collimating lens 231 and secondarily collimating the emitted light. The emitted light is collimated by the fifth and sixth collimator lenses 231 and 232, and then has a predetermined directivity and parallelism.

In some embodiments, a color filter 233 may be disposed on the light-emitting path of the sixth collimating lens 232. The color filter 233 is selected according to the color of the emitted light of the light emitting unit corresponding to the collimating unit where it is located, for example, when the emitted light of the third light emitting unit 13 is blue, a color filter having an anti-blue property will be selected. The color filter 233 having the anti-blue property is used to correct the emitted light passing through the sixth collimating lens 232, which is advantageous in enhancing the color effect of the emitted light. In addition, the color filter 233 is also used to receive and transmit the red emission light passing through the first collimating unit 21 and the green emission light passing through the second collimating unit 22. The color filter 233 thus has the property of transmitting red light and green light while having the property of reflecting blue light. Of course, the performance of the color filter 233 is selected according to the requirements of the location thereof, and the present application is not limited thereto. In addition, by changing the propagation path of the emitted light under the reflection of the color filter 233, the path length required for light propagation is satisfied without expanding the space, and thus the space saving effect is achieved, and in addition, the performance of the projection system can be improved.

In some embodiments, since the first collimating unit 21 and the second collimating unit 22 are far from the optical path of the shaping module 3, the present application adds a correction lens 24 on the light-emitting path of the second collimating unit 22, so as to correct the collimated emitted light passing through the first collimating unit 21 and the second collimating unit 22, so that the emitted light has better projection performance. Of course, the correction lens 24 may be disposed on the light-emitting path of the third collimating unit 23, or the correction lens 24 may be disposed after any collimating unit, which is not limited in this disclosure.

A shaping module 3 may be provided on the light exit path of the dimming module 2. Since the shaping module 3 of the present application is a fly-eye lens, the following description will directly explain the fly-eye lens as the shaping module 3 in more detail.

In one embodiment of the present application, the projection system further comprises: a deflection module 4. The turning module 4 is arranged on the light path between the shaping module 3 and the image generation module 5. The turn-around module 4 is used to emit the collimated emitted light at a predetermined angle, and its specific structure will be described in detail below.

In some embodiments, the fly-eye lens has a substrate (not shown), and sub-lens arrays of a plurality of sub-lenses 31 may be symmetrically disposed at both sides of the substrate. Alternatively, a sub-lens array composed of a plurality of sub-lenses 31 may be provided on either side of the substrate.

In one embodiment of the present application, each sub-lens 31 may have the same size (long side size or wide side size), the same refractive index of material, the same thickness, and the same curvature. In addition, the pitches between the adjacent sub-lenses 31 are the same, i.e., the plurality of sub-lenses 31 are uniformly distributed on both sides or any side of the substrate.

Further, in one embodiment of the present application, the end of each sub-lens 31 close to the substrate is a plane, and the end far from the substrate is a sphere or an aspherical surface having curvature, and the material may be glass or optical plastic. Each sub-lens 31 of the fly-eye lens can independently and independently image on the imaging surface, and the emitted light passing through the fly-eye lens can obtain uniform illuminance on the imaging surface due to superposition of the light emitted by each sub-lens 31 on the imaging surface. Therefore, using a fly-eye lens as the shaping module 3 is advantageous for homogenizing and shaping the emitted light. On the other hand, the light emitted from each sub-lens 31 on the fly-eye lens will be projected on the corresponding area of the imaging surface, wherein the size of the imaging surface area corresponding to each beam of light is the same, and the shape of the light spot formed by the light emitted from each sub-lens 31 after the overlapping of the imaging surfaces is consistent with the shape of the imaging surface.

The special-shaped projection surface 7 in the projection system of the present application is the imaging surface, and the shape of the spot formed by the light projected on the special-shaped projection surface 7 is limited by the shape of each sub-lens 31 of the fly-eye lens based on the above-mentioned performance of the fly-eye lens. In other words, in the conventional projection system, the shape of the projection of the sub-lens 31 of the fly-eye lens in the optical path direction is generally rectangular, and therefore, the shape of the spot formed on the projection surface thereof by the conventional projection system is rectangular.

Further, in order to make the illuminance of the spot obtained on the shaped projection surface 32 meet the requirements, various design parameters of the sub-lenses 31 of the fly-eye lens will satisfy the following relationship:

tansin^-1(d/2nL)＝H/2f，

Wherein d is the long side size or the short side size of the sub-lens 31, and d is not less than 0.05mm; n is the refractive index of the material of the sub-lens 31, and n is more than or equal to 1.5; l is the thickness of the sub-lens 31, and L is not less than 1mm; h is the corresponding long side size or the corresponding short side size of the spot area formed on the special-shaped projection surface 7 by the light emitted by the sub-lens 31; f is the focal length of the optical module between the sub-lens 31 and the shaped projection surface 7.

Further, in an embodiment of the present application, the optical module between the sub-lens 31 and the shaped projection surface 7 may be a projection lens and a folding module.

Further, the sub-lens 31 may be formed by injection molding of COP (Cyclo Olefin Polymers, cycloolefin copolymer) plastic or hot molding of glass. Further, the shaping module 3 may be formed by injection molding of COP plastic or hot molding of glass. The batch production of the micro mirror units is carried out in the mode, so that the production efficiency is improved, and the production time and cost are reduced. Further, any one of the sub-lens 31 and the shaping module 3 can be formed by adopting COP plastic injection molding, and the processing precision of the process is higher, so that burrs of the sub-lens 31 and the shaping module 3 are fewer, the edge sharpness is better, and the imaging image quality of a projection system is optimized.

The present application adjusts the shape of each sub-lens 31 of the fly-eye lens in order to satisfy various shapes of projection surfaces in the projection system. In one embodiment of the present application, the projected shape of the sub-lens 31 on the light path of the emitted light may be at least one of a circle, a triangle, a quadrangle, a pentagon, a hexagon, or any combination thereof. In the following, the specific contents and advantageous effects of the projection system and the manufacturing method thereof provided by the present application are described by taking representative parallelograms and trapezoids of the quadrangles as examples, however, it will be understood by those skilled in the art that the shape of the sub-lenses can be changed to obtain the respective results and advantages described in the present specification without departing from the technical solution claimed by the present application,

Fig. 2 is a schematic diagram of a fly-eye lens configuration with parallelogram-shaped sub-lenses in a projection system according to an exemplary embodiment of the application. Fig. 3 is an enlarged view of area a of the fly's eye lens in fig. 2.

As shown in fig. 1,2 and 3, the projection of each sub-lens 31 of the fly-eye lens in the optical path direction has a parallelogram shape. The sub-lenses 31 are closely arranged in a parallelogram shape in the outline of a rectangular shape and are arranged on one side of a substrate (not shown), and the pitches between adjacent sub-lenses 31 are the same. However, it will be understood by those skilled in the art that the outline of each sub-lens 31 of the fly-eye lens is not limited to the rectangular outline of the present application, but may be a circular outline, an annular outline, or other polygonal outline such as triangle or pentagon, etc., according to the requirements of the projection system.

The emitted light collimated by the dimming module 2 is split into multiple beams of light by a plurality of sub-lenses 31 on the fly-eye lens, wherein each sub-lens 31 corresponds to one beam of light and shapes the light. Further, each sub-lens projects the shaped light to a corresponding area of the special-shaped projection surface 7 through the turning module 4 and the pattern generating module 5. The areas of the special-shaped projection surface 7 corresponding to the light passing through each sub-lens 31 are the same in size, and the light spots formed by the light emitted by each sub-lens 31 after being overlapped on the special-shaped projection surface 7 are in the shape of parallelograms and are the same as the parallelograms of the sub-lenses 31.

Fig. 4 is a light spot effect diagram of a projection system using the fly-eye lens of fig. 2 on a projection surface.

As shown in fig. 4, the shape S1 of the projection of the sub-lenses 31 of the fly-eye lens in the optical path direction in the present embodiment is a parallelogram, and therefore, the spot shape formed by superimposing the light emitted from each sub-lens 31 of the fly-eye lens on the projection surface is a parallelogram. The projection system is convenient to be matched with the special-shaped projection surface 7 with the shape of a parallelogram, and the process difficulty of the projection system is not increased. Furthermore, the addition of redundant optical elements in the projection system can be avoided, the lightness and thinness of the projection system are ensured, and the reduction of the working efficiency caused by adding the optical elements of the projection system or adjusting the working parameters of the original optical elements in the prior art is avoided.

Fig. 5 is a schematic diagram of a fly-eye lens configuration with trapezoidal shaped sub-lenses in a projection system according to an exemplary embodiment of the application. Fig. 6 is an enlarged view of region B of the fly's eye lens in fig. 5.

As shown in fig. 1, 5 and 6, the projection of each sub-lens 31 of the fly-eye lens in the optical path direction has a trapezoidal shape. The sub-lenses 31 are closely arranged on one side of a substrate (not shown) in a rectangular arrangement by sequentially staggered sub-lenses 31 of positive and negative trapezoids, and the pitches between adjacent sub-lenses 31 are the same. However, it will be understood by those skilled in the art that the arrangement of the sub-lenses 31 of the fly-eye lens is not limited to the rectangular arrangement of the present application, but may be circular, or other polygonal arrangements such as triangular or pentagonal, etc., according to the requirements of the projection system.

The emitted light collimated by the dimming module 2 is split into multiple beams of light by a plurality of sub-lenses 31 on the fly-eye lens, wherein each sub-lens 31 corresponds to one beam of light and shapes the light. Further, each sub-lens projects the shaped light to a corresponding area of the special-shaped projection surface 7 through the turning module 4 and the pattern generating module 5. The projection surface areas corresponding to the light passing through each sub-lens 31 are the same in size, and the light spot shape formed by overlapping the light emitted by each sub-lens 31 on the special-shaped projection surface 7 is a hexagon formed by combining a positive trapezoid and an inverse trapezoid, and corresponds to the trapezoid shape of the sub-lens 31. Fig. 7 is a light spot effect diagram of a projection system using the fly-eye lens of fig. 5 on a projection surface.

As shown in fig. 7, the shape S2 of the projection of the sub-lens 31 of the fly-eye lens in the optical path direction is a trapezoid, and two adjacent sub-lenses are arranged in a manner that the positive and negative trapezoids intersect, so that the spot shape formed by the light emitted from each sub-lens of the fly-eye lens after the superposition of the projection surfaces is a hexagon formed by combining the positive and negative trapezoids, the central part of the spot has higher illuminance, the area illuminance of the edge triangle is very low, and the imaging effect of the hexagon spot is not affected. The projection system is convenient to use in cooperation with a hexagonal projection surface formed by combining a positive trapezoid and an inverse trapezoid, and the process difficulty of the projection system is not increased. Furthermore, the addition of redundant optical elements in the projection system can be avoided, the lightness and thinness of the projection system are ensured, and the reduction of the working efficiency caused by adding the optical elements of the projection system or adjusting the working parameters of the original optical elements in the prior art is avoided.

However, it will be understood by those skilled in the art that the shape of the projection of the sub-lenses of the fly-eye lens in the optical path direction is not limited to the parallelogram or trapezoid, and may be other polygons, for example, a circle, a triangle, other quadrangles or pentagons, etc., and may be set according to the requirements of the shaped projection surface. In the case where the superimposed projection shape of the sub-lenses of the fly-eye lens in the optical path direction is the same as the opposite projection surface, the sub-lenses may be designed to be arbitrary shapes.

Fig. 9 is a schematic diagram of the morphology of triangular sub-lenses in a fly-eye lens according to an exemplary embodiment of the application. Fig. 10 is a graph of the effect of achieving a parallelogram spot on a projection surface including a fly-eye lens employing the sub-lenses of fig. 9. Fig. 11 is a diagram of a hexagonal spot effect achieved on a projection surface including a fly-eye lens employing the sub-lenses of fig. 9. Fig. 12 is a graph of the effect of pentagonal spots on a projection surface that includes a fly-eye lens employing the sub-lenses of fig. 9.

Alternatively, the projection position of each sub-lens on the special-shaped projection surface can be controlled by selecting the sub-lenses with simple shapes and controlling the sizes and mutual distances (size and arrangement design) of the sub-lenses so as to realize the anisotropic projection of the complex shapes. In addition, the adjacent sub-lenses are arranged in a side length mutual splicing mode, so that the arrangement of the sub-lenses in the fly-eye lens is more compact, and the light utilization rate is improved.

Specifically, as shown in fig. 9, in one embodiment of the present application, the sub-lenses in the fly-eye lens may be selected to have a triangular shape. Further, by adjusting the size and arrangement of the triangular sub-lenses, the anisotropic projection of complex shapes can be realized.

As shown in fig. 10, in one embodiment of the present application, a plurality of triangular-shaped sub-lenses can realize a shaped projection of a parallelogram by adjusting the size and arrangement of the triangular-shaped sub-lenses.

As shown in fig. 11, in one embodiment of the present application, a plurality of triangular sub-lenses may further implement hexagonal shaped projection (as shown by the solid line portion in the figure) by adjusting the size and arrangement of the triangular sub-lenses.

As shown in fig. 12, in one embodiment of the present application, a plurality of triangular-shaped sub-lenses may further implement a pentagonal shaped projection (as shown in the solid line portion of the figure) by adjusting the size and arrangement of the triangular-shaped sub-lenses.

Fig. 13 is a distribution diagram of sub-lenses in a circular arrangement according to an exemplary embodiment of the present application. Fig. 14 is a sub-lens distribution diagram in a rectangular arrangement according to an exemplary embodiment of the present application.

As shown in fig. 13 and 14, the fly-eye lens may include a plurality of sub-lenses arranged in a certain arrangement manner, where the arrangement manner of the sub-lenses is that any one of the sub-lenses is taken as a center, for example, any one of the sub-lenses located at a, b, c or d in the figure is taken as a center, and adjacent sub-lenses are combined along a direction away from the center, and finally, the sub-lenses are overlapped in the optical path direction to form a shape conforming to the special-shaped projection plane.

In one embodiment of the application, as shown in fig. 13, when the sub-lenses are required to meet a circular projection surface, a circular arrangement may be performed. In other words, for example, the sub-lenses at a or b may be used as the center, and adjacent sub-lenses with the center may be combined circularly in a direction away from the center, and finally superimposed in the optical path direction of the emitted light to form a shape conforming to the circular projection surface.

In one embodiment of the application, as shown in fig. 14, rectangular arrangements may be made when the sub-lenses are required to meet the parallelogram projection surfaces. In other words, for example, the sub-lens at c or d may be used as a center, and adjacent sub-lenses with the center may be combined in a rectangular shape in a direction away from the center, and finally superimposed in the optical path direction of the emitted light to form a shape conforming to the parallelogram projection surface.

Further, the projection system including fly's eye lenses provided by the application can form any one arrangement or combination of triangular arrangement, pentagonal arrangement, hexagonal arrangement and the like. The sub lenses are arranged, and finally, the sub lenses can be overlapped in the light path direction of the emitted light to form a shape conforming to the special-shaped projection surface. Therefore, the space of the projection system can be effectively saved, and the light utilization rate of the projection system can be improved. It will be appreciated by those skilled in the art that the present application is not limited to the above arrangements of the sub-lenses in the fly-eye lens, and the present application is not limited thereto.

Referring again to fig. 1, in one embodiment of the present application, the turning module 4 may include a first relay lens 41, a reflective mirror 42, a second relay lens 43, and a double prism unit 44.

The first relay lens 41 is configured to receive the homogenized and shaped reflected light emitted from the shaping module 3, and to converge or diffuse the reflected light according to the size of the pattern generating module 5. The mirror 42 is used to reflect the light path. The second relay lens 43 is disposed on the light-emitting path of the reflective mirror 42, and its function is the same as that of the first relay lens 41, and will not be described again.

Further, the biprism unit 44 may be used to redirect the light emitted from the second relay lens 43 onto the pattern generating module 5, and redirect the light with display information emitted from the pattern generating module 5 onto the projection module 6. Of course, the double prism unit 44 may be replaced with a single prism unit or a field lens unit according to different production conditions and requirements, and the specific choice of components is not limited herein.

In some embodiments, the image generating module 5 is configured to receive the shaped light spot transmitted by the turning module 4 and projected by the shaping module 3, and generate an image with the same shape as the shaped projection surface 7.

In some embodiments, the pattern generation module 5 may be a digital micromirror device, i.e. one or several of a DMD module, a MEMS module, and an LCOS module. The shape of the receiving surface of the digital micromirror device is identical to the shape of the sub-lens of the fly-eye lens. Specifically, the shape of the receiving surface of the digital micromirror device is generally rectangular, and the sub-lenses 31 in the shaping module 3 provided by the present application may be various shapes, so in one embodiment of the present application, the shape of the receiving surface of the digital micromirror device may be various special shapes, and the shapes of the sub-lenses of the fly's eye lenses are consistent; in another embodiment of the present application, the shape of the receiving surface of the dmd may be rectangular, and the light emitted from the shaping module 3 should be projected within the effective area of the receiving surface of the dmd, and it is noted that the shape of the sub-lens refers to the projected shape of the sub-lens on the light path of the emitted light.

In some embodiments, the pattern generation module 5 is in a spatial coordinate system as shown in fig. 1. The X-axis direction, the Y-axis direction, and the Z-axis direction of the pattern generating module 5 respectively correspond to the side length direction of the shaping module 3, and if the illuminance of the emitted light received by the pattern generating module 5 is not uniform, at least one of the side length dimension, the thickness, the refractive index of the material, or the radius of curvature of the sub-lenses of the pattern generating module 5 may be adjusted so that the emitted light has uniform illuminance.

In addition, the present application provides a method 1000 for preparing a projection system, the method 1000 comprising:

Step S1, a shaping module is arranged on the light path of the emitted light of the light source module, wherein the shaping module is composed of a plurality of sub lenses.

And S2, setting a special-shaped projection surface on an emergent light path of the shaping module.

And S3, setting the projection shape of the sub-lenses in the light path direction to be the same as or corresponding to the shape of the special-shaped projection surface, so that the projection of the plurality of sub-lenses in the light path direction is overlapped with each other and then is the same as the shape of the special-shaped projection surface.

In some embodiments, the light source module may be configured with a first light emitting unit, a second light emitting unit, and a third light emitting unit. The first, second, and third light emitting units provide monochromatic light sources of three colors of red, green, and blue (RGB), respectively, for example, the first light emitting unit may emit red light, the second light emitting unit may emit green light, and the third light emitting unit may emit blue light. Of course, the positions of the three light emitting units can be replaced according to the requirement, and the application is not limited thereto. Further, the light source module adjusts the proportion of the emitted light of the first light emitting unit, the second light emitting unit and the third light emitting unit according to the color of the emitted light required by the projection system, so that the color of the emitted light of the light source module meets the requirement of the projection system.

In some embodiments, the three light emitting units of the light source module may employ an LED (LIGHT EMITTING Diode) light source or an LD (Laser Diode) light source. Although only two types of light sources are exemplified here, the specific embodiment of the light emitting unit of the present embodiment is not limited thereto.

In an embodiment of the present application, the three light emitting units of the light source module employ LED light sources. Since the emitted light of the LED light source has divergence, when the LED light source is used as the three light emitting units of the light source module, the dimming module needs to be provided to collimate the emitted light of the three light emitting units, respectively, so as to improve the directivity of the emitted light, so that the emitted light can be parallel as much as possible. If the directivities of the emitted lights of the three light emitting units of the light source module are sufficiently high and sufficiently parallel to each other, the number of collimator lenses used in the dimming module may be appropriately reduced or the use of the dimming module may be directly omitted in the embodiment of the present application.

The dimming module may be provided with a first collimating unit, a second collimating unit and a third collimating unit. The first collimating unit is arranged on the light-emitting path of the first light-emitting unit and is used for collimating the emitted light of the first light-emitting unit. The second collimation unit is arranged on the light-emitting path of the second light-emitting unit and is used for collimating the emitted light of the second light-emitting unit. The third collimation unit is arranged on the light-emitting path of the third light-emitting unit and is used for collimating the emitted light of the third light-emitting unit.

Further, the first collimating unit may be provided with a first collimating lens and a second collimating lens. The first collimating lens and the second collimating lens are sequentially arranged on the light-emitting path of the first light-emitting unit. The side of the first collimating lens far away from the first light emitting unit is a mirror surface with curvature. The first collimating lens is used for receiving the emitted light of the first light emitting unit and performing primary collimation. Both sides of the second collimating lens are mirror surfaces with curvature. The second collimating lens is used for receiving the emitted light passing through the first collimating lens and secondarily collimating the emitted light. The emitted light has a predetermined directivity and parallelism after being collimated by the first collimating lens and the second collimating lens.

In some embodiments, a color filter may be disposed on the light-emitting path of the second collimating lens. The color filter is selected according to the color of the emitted light of the corresponding light emitting unit of the collimation unit, for example, when the emitted light of the first light emitting unit is red, the color filter with anti-red performance is selected. The color filter with anti-red performance is used for correcting the emitted light passing through the second collimating lens, which is beneficial to enhancing the color effect of the emitted light. In addition, under the reflection action of the color filter, the propagation path of the emitted light is changed, so that the path length required by light propagation is met under the premise of not expanding space, the space saving effect is achieved, and the performance of the projection system can be improved.

In some embodiments, a second collimating unit may be disposed on the light-emitting path of the first collimating unit. The second collimating unit is used for collimating the emitted light of the second light emitting unit. The second collimating unit may include a third collimating lens and a fourth collimating lens. The third collimating lens and the fourth collimating lens are sequentially arranged on the light-emitting path of the second light-emitting unit. The side of the third collimating lens far away from the second light-emitting unit is a mirror surface with curvature. The third collimating lens is used for receiving the light emitted by the second light-emitting unit and performing primary collimation. Both sides of the fourth collimating lens are mirror surfaces with curvature. The fourth collimating lens is used for receiving the emitted light passing through the third collimating lens and performing secondary collimation on the emitted light. After the emitted light is collimated by the third collimating lens and the fourth collimating lens, the emitted light has preset directivity and parallelism.

In some embodiments, a color filter may be disposed on the light-emitting path of the fourth collimating lens. The color filter is selected according to the color of the emitted light of the corresponding light emitting unit of the collimation unit where the color filter is located, for example, when the emitted light of the second light emitting unit is green, the color filter with anti-green performance is selected. The color filter with anti-green performance is used for correcting the emitted light passing through the fourth collimating lens, which is beneficial to enhancing the color effect of the emitted light. In addition, the color filter is also configured to receive and transmit red-emitting light passing through the first collimating unit. Therefore, the color filter has the property of reflecting green light and transmitting red light. Of course, the performance of the color filter is selected according to the requirements of the location thereof, and the present application is not limited thereto. In addition, under the reflection action of the color filter, the propagation path of the emitted light is changed, so that the path length required by light propagation is met under the premise of not expanding space, the space saving effect is achieved, and the performance of the projection system can be improved.

In some embodiments, a third collimating unit may be disposed on the light-emitting path of the second collimating unit. The third collimating unit is used for collimating the emitted light of the third light emitting unit. The third collimating unit may include a fifth collimating lens and a sixth collimating lens. The fifth collimating lens and the sixth collimating lens are sequentially arranged on the light-emitting path of the third light-emitting unit. The side of the fifth collimating lens far away from the third light-emitting unit is a mirror surface with curvature. The fifth collimating lens is used for receiving the emitted light of the third light-emitting unit and performing primary collimation. Both sides of the sixth collimating lens are mirror surfaces with curvature. The sixth collimating lens is used for receiving the emitted light passing through the fifth collimating lens and performing secondary collimation on the emitted light. After the emitted light is collimated by the fifth collimating lens and the sixth collimating lens, the emitted light has preset directivity and parallelism.

In some embodiments, a color filter may be disposed on the light-emitting path of the sixth collimating lens. The color filter is selected according to the color of the emitted light of the light emitting unit corresponding to the collimation unit where the color filter is located, for example, when the emitted light of the third light emitting unit is blue, the color filter with anti-blue performance is selected. The color filter with blue-reflecting performance is used for correcting the emitted light passing through the sixth collimating lens, which is beneficial to enhancing the color effect of the emitted light. In addition, the color filter is also used for receiving and transmitting red emission light passing through the first collimating unit and green emission light passing through the second collimating unit. The color filter has the property of reflecting blue light and transmitting red light and green light. Of course, the performance of the color filter is selected according to the requirements of the location thereof, and the present application is not limited thereto. In addition, under the reflection action of the color filter, the propagation path of the emitted light is changed, so that the path length required by light propagation is met under the premise of not expanding space, the space saving effect is achieved, and the performance of the projection system can be improved.

In some embodiments, since the first collimating unit and the second collimating unit are far from the optical path of the shaping module, the present application adds a correcting lens on the light-emitting path of the second collimating unit, so as to correct the light emitted after being collimated by the first collimating unit and the second collimating unit, so that the light emitted has better projection performance. Of course, the correction lens may be disposed on the light-emitting path of the third collimating unit, or disposed after any collimating unit, which is not limited herein.

In some embodiments, the method for preparing a projection system provided by the present application further includes: the light modulation module is arranged on the light emitting path of the light source module and between the light source module and the shaping module, wherein at least one correcting lens is arranged in the light modulation module.

A shaping module may be disposed on the light-emitting path of the dimming module. Since the reshaping module of the present application is a fly-eye lens, the following description will directly explain the fly-eye lens as the reshaping module in more detail.

In some embodiments, the fly-eye lens has a base (not shown) and sub-lens arrays including a plurality of sub-lenses are symmetrically disposed on both sides of the base to form a shaping module; or alternatively a sub-lens array comprising a plurality of sub-lenses is arranged on either side of the substrate to form a shaping module.

In some embodiments, the shape of the plurality of sub-lenses may be the same, i.e., each sub-lens has the same dimensions (long side dimension, wide side dimension, perimeter dimension, etc.), the same refractive index of the material, the same thickness, and the same curvature.

In addition, alternatively, the spacing between adjacent sub-lenses is the same, i.e., the plurality of sub-lenses are uniformly distributed on both sides or on either side of the substrate.

Further, one end of each sub-lens close to the substrate is a plane, and one end of each sub-lens far away from the substrate is a sphere or an aspheric surface with curvature, and the material of each sub-lens can be glass or optical plastic. Each sub-lens of the fly-eye lens can independently and independently image on the imaging surface, and the emitted light passing through the fly-eye lens can obtain uniform illumination on the imaging surface due to superposition of the light emitted by each sub-lens on the imaging surface. Therefore, using a fly-eye lens as a shaping module is advantageous for homogenizing and shaping the emitted light. On the other hand, the light emitted by each sub-lens on the fly-eye lens is projected on the corresponding area of the imaging surface, wherein the size of the imaging surface area corresponding to each beam of light is the same, and the shape of a light spot formed by the light emitted by each sub-lens after the overlapping of the imaging surfaces is consistent with the shape of the imaging surface.

In the projection system of the present application, the shape of the light spot formed by the light projected on the irregular projection surface, that is, the imaging surface, is limited by the image generating module, for example, DMD, MEMS, LCOS, and the size of the display chip, based on the performance of the fly-eye lens, and therefore, the shape of the receiving surface of the display chip is limited by the shape of each sub-lens of the fly-eye lens. In other words, in the conventional projection system, the shape of projection of the sub-lenses of the fly-eye lens in the optical path direction is generally rectangular, and therefore, the shape of the spot formed by superimposing the conventional projection system on the projection surface thereof is rectangular.

Further, in order to make the illuminance of the spot obtained on the projection surface meet the requirements, various design parameters of the sub-lenses of the fly-eye lens will satisfy the following relationship:

tansin^-1(d/2nL)＝H/2f，

Wherein d is the long side size or the wide side size of the subunit, and d is more than or equal to 0.05mm; n is the refractive index of the material of the sub-lens, and n is more than or equal to 1.5; l is the thickness of the sub-lens, and L is more than or equal to 1mm; h is the corresponding long side size or the corresponding wide side size of a light spot area formed on the projection surface by the light emitted by the sub-lens; f is the focal length of the optical module between the sub-lens and the shaped projection surface.

Further, the optical module between the sub-lens and the shaped projection surface may be a projection lens and a refractive module.

In one embodiment of the present application, the shape of the projection of the sub-lens on the light path of the emitted light may be at least one of a circle, a triangle, a parallelogram, a trapezoid, and a pentagon, or any combination thereof.

Specifically, according to the fly-eye lens provided by the embodiment of the application, the projection positions of the sub-lenses on the special-shaped projection surface can be controlled by selecting the sub-lenses with simple shapes and controlling the sizes and mutual distances (size and arrangement design) of the sub-lenses so as to realize the anisotropic projection of the complex shapes. In addition, the adjacent sub-lenses are arranged in a side length mutual splicing mode, so that the arrangement of the sub-lenses in the fly-eye lens is more compact, and the light utilization rate is improved.

Further, the sub-lenses may be injection molded using COP (Cyclo Olefin Polymers, cycloolefin copolymer) plastic or glass hot molded. Further, the shaping module can also be formed by adopting COP plastic injection molding or glass hot molding. The fly-eye lens with a plurality of sub-lenses is produced in batches in the mode, so that the production efficiency is improved, and the production time cost is reduced.

In order to meet various shapes of the special-shaped projection surface in the projection system, the application adjusts the shapes of all sub-lenses of the fly-eye lens.

In one embodiment, the shape of the projection of each sub-lens of the fly-eye lens in the optical path direction is a parallelogram. The sub-lenses are closely arranged in a rectangular shape in a parallelogram shape and arranged on one side of the substrate, and the pitches between adjacent sub-lenses are the same. However, it should be understood by those skilled in the art that the shaping module is formed by a plurality of sub-lenses, the arrangement is that any one sub-lens is taken as a center, and adjacent sub-lenses are combined into a fixed shape distribution along the direction away from the center, so as to form any one or combination of arrangement modes of rectangular arrangement, circular arrangement, annular arrangement, triangular arrangement and pentagonal arrangement, and finally, the sub-lenses are arranged, so that the shape conforming to the special-shaped projection surface can be formed in the light path direction of the emitted light in a superposition manner. Therefore, the space of the projection system can be effectively saved, and the light utilization rate of the projection system can be improved. The arrangement of the sub-lenses in the fly-eye lens is not limited to the above form, and the present application is not limited thereto.

The emitted light collimated by the dimming module is divided into a plurality of beams of light by a plurality of sub-lenses on the fly-eye lens, wherein each sub-lens corresponds to one beam of light and is shaped. Further, each sub-lens projects the shaped light to a corresponding area of the special-shaped projection surface through the turning module and the pattern generating module. The size of the projection surface area corresponding to the light passing through each sub-lens is the same, and the light spot shape formed by the light emitted by each sub-lens after the superposition of the projection surfaces is parallelogram and is the same as the shape of the sub-lens.

In some embodiments, the shape of the projection of the sub-lenses of the fly-eye lens in the optical path direction is a parallelogram, so the spot shape formed by the light emitted from each sub-lens of the fly-eye lens after the superposition of the projection surfaces is a parallelogram. The projection system is convenient to use in cooperation with the projection surface with the shape of a parallelogram, and meanwhile, the process difficulty of the projection system is not increased. Furthermore, the addition of redundant optical elements in the projection system can be avoided, the lightness and thinness of the projection system are ensured, and the reduction of the working efficiency caused by adding the optical elements of the projection system or adjusting the working parameters of the original optical elements in the prior art is avoided.

In some embodiments, the shape of the projection of each sub-lens of the fly-eye lens along the optical path direction is trapezoidal. The sub-lenses can be closely arranged on one side of the substrate in a rectangular mode in a staggered manner in a positive trapezoid and an inverted trapezoid, and the spacing between the adjacent sub-lenses is the same. However, it should be understood by those skilled in the art that the arrangement of the sub-lenses of the fly-eye lens is not limited to the rectangular arrangement of the present application, but may be circular, annular, or other polygonal arrangements such as triangle or pentagon, etc., according to the requirements of the projection system.

The emitted light collimated by the dimming module is divided into a plurality of beams of light by a plurality of sub-lenses on the fly-eye lens, wherein each sub-lens corresponds to one beam of light and is shaped. Further, each sub-lens projects the shaped light to a corresponding area of the special-shaped projection surface through the turning module and the pattern generating module. The light spot shape formed by the light emitted by each sub-lens after superposition of the projection surfaces is a hexagon formed by combining positive and reverse trapezoids, and the light spot shape is the same as or similar to the shape of the sub-lens.

In some embodiments, the sub-lenses of the fly-eye lens have a trapezoid shape in projection along the light path direction, and two adjacent sub-lenses are arranged in a way that positive and negative trapezoids intersect, so that the light spot shape formed by overlapping the light emitted by each sub-lens of the fly-eye lens on the projection surface is a hexagon formed by combining the positive and negative trapezoids, the central part of the light spot has higher illuminance, and the edge part of the light spot gradually decreases. The projection system is convenient to use in cooperation with a hexagonal projection surface formed by combining a positive trapezoid and an inverse trapezoid, and the process difficulty of the projection system is not increased. Furthermore, the addition of redundant optical elements in the projection system can be avoided, the lightness and thinness of the projection system are ensured, and the reduction of the working efficiency caused by adding the optical elements of the projection system or adjusting the working parameters of the original optical elements in the prior art is avoided.

In some embodiments, the turning module may include a first relay lens, a reflective color filter, a second relay lens, and a biprism unit.

The first relay lens is used for receiving the homogenized and shaped reflected light emitted by the shaping module and converging or diffusing the reflected light according to the size of the pattern generating module. The second relay lens is disposed on the light-emitting path of the reflective color filter, and its function is the same as that of the first relay lens, and will not be described again.

Further, the projection system further includes a projection module, the projection module may include a plurality of lenses, and the biprism unit may be configured to fold the light emitted from the second relay lens onto the pattern generating module, and fold the light emitted from the pattern generating module with display information onto the projection module. Of course, the double prism unit may be replaced with a single prism unit or a field lens unit according to different production conditions and requirements, and specific element choices are not limited herein.

In some embodiments, the pattern generation module may be a digital micromirror device, i.e., one or more of a DMD module, a MEMS module, and an LCOS module. The shape of the digital micromirror device is consistent with the shape of the fly-eye lens micromirror lens.

In some embodiments, the image generating module is configured to receive the shaped light spot transmitted by the turning module and projected by the shaping module, and generate an image with the same shape as the shaped projection surface.

In some embodiments, the pattern generation module is in a spatial coordinate system. The X-axis direction, the Y-axis direction, and the Z-axis direction of the pattern generating module respectively correspond to the side length direction of the shaping module, and if the illuminance of the emitted light received by the pattern generating module is not uniform, at least one of the side length dimension, the thickness, the refractive index of the material, or the radius of curvature of the sub-lenses of the pattern generating module can be adjusted so that the emitted light has uniform illuminance.

Claims

1. A projection system, comprising:

a light source module for generating emitted light; and

A special-shaped projection surface;

Wherein the projection system further comprises:

The shaping module is arranged on the light path of the emitted light and is positioned between the light source module and the special-shaped projection surface, the shaping module comprises a plurality of sub lenses, the projection shape of the sub lenses in the light path direction corresponds to the shape of the special-shaped projection surface, and the projection shapes of the sub lenses in the light path direction are overlapped with each other and then are identical to the shape of the special-shaped projection surface.

2. The projection system of claim 1, wherein the shape of the projection of the sub-lenses onto the light path of the emitted light is at least one of a circle, triangle, parallelogram, trapezoid, and pentagon, or any combination thereof.

3. The projection system of claim 1 or 2, wherein a plurality of the sub-lenses have the same shape, the same size, the same material refractive index, the same thickness, and the same curvature.

4. The projection system of claim 1 or 2, wherein the arrangement of the plurality of sub-lenses comprises any one or a combination of a rectangular arrangement, a circular arrangement, an annular arrangement, a triangular arrangement, and a pentagonal arrangement.

5. The projection system of claim 4 wherein adjacent ones of the sub-lenses have the same spacing therebetween.

6. The projection system of claim 1 or 2, wherein the shaping module further comprises a substrate, and a sub-lens array comprising a plurality of the sub-lenses is symmetrically arranged on both sides of the substrate or a sub-lens array comprising a plurality of sub-lenses is arranged on either side of the substrate.

7. The projection system according to claim 1 or 2, wherein a corresponding size H of a spot area formed on the shaped projection surface by the light emitted from the sub-lens and a size d of the sub-lens corresponding to the size H of the shaped projection surface satisfy:

tansin^-1(d/2nL)=H/2f，

8. The projection system according to claim 1 or 2, wherein in the case where the shape of the shaped projection surface is hexagonal, the shape of projection of the sub-lens in the optical path direction of the emitted light corresponds to the shape of the shaped projection surface, and the shape of projection of the sub-lens is trapezoidal.

9. The projection system of claim 1 or 2, wherein the shaping module is made of at least one of a cyclic olefin copolymer COP plastic or glass.

10. The projection system of claim 1 or 2, wherein the shaping module is prepared by at least one of an injection molding process or a thermal molding process.

11. The projection system of claim 1 or 2, wherein the light source module comprises any one or a combination of RGB monochromatic light sources.

12. The projection system of claim 1 or 2, wherein the light source module comprises at least one of an LED light source and a laser light source.

13. The projection system of claim 1 or 2, further comprising a dimming module comprising at least one collimating lens and at least one color filter.

14. The projection system of claim 1 or 2, further comprising a dimming module, the dimming module further comprising at least one corrective lens.

15. The projection system of claim 1 or 2, further comprising a turning module comprising at least one relay lens, at least one mirror, and at least one right angle prism.

16. The projection system of claim 1 or 2, further comprising an image generation module comprising one or more of a DMD module, a MEMS module, and an LCOS module.

17. The projection system according to claim 1 or 2, further comprising a deflection module and an image generation module, wherein the image generation module is configured to receive the shaped light spot transmitted by the deflection module and projected by the shaping module, and generate an image with the same shape as the shaped projection surface.

18. A method of making a projection system, the method comprising:

A shaping module is arranged on a light path of the emitted light of the light source module, wherein the shaping module is composed of a plurality of sub lenses; and

A special-shaped projection surface is arranged on the light path,

The projection shape of the sub-lenses in the light path direction is set to be corresponding to the shape of the special-shaped projection surface, so that the projection of the plurality of sub-lenses in the light path direction is overlapped with each other and then is identical to the shape of the special-shaped projection surface.

19. The method of claim 18, wherein the shaping module is comprised of a plurality of sub-lenses comprising:

the projection shape of the sub-lens on the light path of the emitted light is set to at least one of a circle, a triangle, a parallelogram, a trapezoid, and a pentagon, or any combination thereof.

20. The method of claim 18 or 19, wherein the shaping module is comprised of a plurality of sub-lenses comprising:

a plurality of the sub-lenses are arranged in the same shape, the same size, the same material refractive index, the same thickness, and the same curvature to form the shaping module.

21. The method of claim 18 or 19, wherein the shaping module is comprised of a plurality of sub-lenses comprising:

And arranging a plurality of the sub lenses in any one or combination of rectangular arrangement, circular arrangement, annular arrangement, triangular arrangement and pentagonal arrangement to form the shaping module.

22. The method of claim 21, wherein the shaping module is comprised of a plurality of sub-lenses comprising:

and setting the spacing between adjacent sub-lenses to be the same so as to form the shaping module.

23. The method of claim 18 or 19, the shaping module further comprising a substrate, wherein the shaping module is comprised of a plurality of sub-lenses comprising:

symmetrically arranging sub-lens arrays comprising a plurality of sub-lenses on two sides of the substrate to form the shaping module; or a sub-lens array comprising a plurality of sub-lenses is arranged on any side of the substrate to form the shaping module.

24. The method according to claim 18 or 19, wherein setting the shape of the projection of the sub-lens in the optical path direction and the shape of the shaped projection surface to correspond to each other comprises:

The corresponding size H of a light spot area formed by the light emitted by the sub-lens on the special-shaped projection surface and the size d of the sub-lens corresponding to the size H of the special-shaped projection surface satisfy the following conditions:

tansin^-1(d/2nL)=H/2f，

25. The method according to claim 18 or 19, wherein setting the shape of the projection of the sub-lens in the optical path direction and the shape of the shaped projection surface to correspond to each other comprises:

When the shape of the irregular projection surface is hexagonal, the shape of the projection of the sub-lens in the optical path direction of the emitted light is set to correspond to the shape of the irregular projection surface, and the shape of the projection of the sub-lens is trapezoidal.

26. The method of claim 18 or 19, wherein forming the shaping module with a plurality of sub-lenses comprises:

the sub-lenses are prepared from at least one of a cyclic olefin copolymer, COP, plastic or glass to form the shaping module.

27. The method of claim 18 or 19, wherein forming the shaping module with a plurality of sub-lenses comprises:

the sub-lenses are prepared by at least one of an injection molding process or a thermal molding process to form the shaping module.

28. The method according to claim 18 or 19, characterized in that the method comprises:

any one or a combination of RGB single-color light sources is arranged in the light source module.

29. The method according to claim 18 or 19, characterized in that the method comprises:

At least one of an LED light source and a laser light source is provided in the light source module.

30. The method according to claim 18 or 19, characterized in that the method further comprises:

the dimming module is disposed on the light-emitting path of the light source module,

Wherein at least one collimating lens and at least one color filter are disposed in the dimming module.

31. The method according to claim 18 or 19, characterized in that the method further comprises:

Wherein at least one corrective lens is disposed in the dimming module.

32. The method of claim 30, wherein the method further comprises:

the turn-around module is arranged on the light-out path of the dimming module,

Wherein, set up at least one relay lens in the turn over module, at least one reflector and at least one right angle prism.

33. The method of claim 31, further comprising:

the turn-around module is arranged on the light-out path of the dimming module,

34. The method according to claim 18 or 19, characterized in that the method further comprises:

an image generation module is arranged in the projection system, and the image generation module comprises one or more of a DMD module, a MEMS module and an LCOS module.

35. The method according to claim 18 or 19, characterized in that the method further comprises:

The projection system is provided with a deflection module and an image generation module, wherein the image generation module is used for receiving the special-shaped light spots transmitted by the deflection module and projected by the sizing module and generating images with the same shape as the special-shaped projection surface.