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Coupling light efficiently onto today's small LCD and other spatial light modulators has become an increasing problem. Even with the best short-arc lamps, output spot sizes are 20-25 mm or more when matched to a standard f/3 projection lens. But state-of-the-art microdisplays are as little as 10-15 mm diagonal, so 50% or more of the light is never collected. Much of this excess spot size results from optical distortions introduced by curren collection optics. Our developmental illuminators produce up to 50% smaller spot sizes by avoiding these distortions, and achieving collection efficiency approaching the fundamental limits of arc size and projection lens numerical aperture. Although our specific architecture is still proprietary, it is based on our non-imaging optics technology foundation. Each design must be optimized to a selected light source, light-valve, and projection lens. Cost is slightly higher than conventional collection optics, since an additional element must be added to the system. Manufacturing techniques should be similar to those used for conventional collection optics, so the additional cost should be a modest fraction of the overall illumination subsystem. The technology has been demonstrated in the lab, and is currently being refined and hardened for commercialization. It can be applied to a wide variety of light sources and projector systems, with turn-around time and development costs comparable to standard custom optics. Similar techniques can be used to enhance the efficiency of fiber-optic illumination systems.
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