DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0039] The present inventors have determined that a positive, firm strike from a dislodging tool, such as a razor blade or chisel, can effectively break the adhesive layer between a microdisplay and an optical component without incurring damage to the microdisplay or prism. Damage to the microdisplay is more likely if the dislodging tool strikes at the microdisplay. Therefore the dislodging tool must be guided to impact only the adhesive layer. However, it is preferable that the strike occur at the interface between an adhesive layer (e.g., see adhesive layer 330 in FIG. 3A ) and the optical component, and that the strike be as near as possible to parallel with a surface of the optical component to which the microdisplay is mounted.

[0040] Referring again to the drawings, wherein like reference numerals designate identical or corresponding parts, and more particularly to FIG. 3A thereof, there is illustrated a package for mounting a microdisplay 320 to a Polarizing Beam Splitter (PBS) 300 . The package may be used to mount the microdisplay 320 to a PBS, prism, or other optical equipment. The package may also be used to mount other sensitive electronics or optical devices to any surface. The illustrated PBS is part of a light engine and is constructed of two prisms 305 and 310 . An upper surface 312 of prism 310 is used for mounting the microdisplay 320 . In this embodiment, the microdisplay 320 is preferably attached to the prism upper surface 312 via adhesive 330 (e.g., UV cured optical adhesive). Thus, a face of the microdisplay is bonded to a face (e.g., upper surface 312 ) of the prism with an adhesive.

[0041] The package includes a carrier 325 , which is preferably a flat ceramic plate. However, other materials may be substituted instead of ceramics. The carrier also preferably provides means (electrical connections, through holes, etc) to make electrical contact or connections for energizing and sending image or other data to the microdisplay 320 . The carrier itself may extend beyond one or more edges of the microdisplay 320 . The extension of the carrier causes the carrier to overhang the microdisplay. The extension, or overhang, acts as a guide that helps guide insertion of a dislodging tool (e.g., chisel 340 ) at an angle such that the chisel contacts the adhesive. Contacting only the adhesive (or interface between the adhesive and prism 310 ) prevents damage that would likely occur to the microdisplay if it was directly impacted by the dislodging tool (e.g., tool 345 ).

[0042] An optional bezel 335 is preferably attached to at least one portion of the carrier. In one embodiment, the bezel surrounds the microdisplay and is bonded to the carrier (e.g., bonded to the carrier overhang). The bezel extends below the microdisplay, protecting it from direct impact with any object, including any dislodging tools. Preferably, the bezel provides an opening or “notch” 352 , for inserting the striking end of a dislodging tool. For example, a dislodging tool 340 is inserted between the prism face 312 and the microdisplay 320 , preferably at the interface of the prism surface 312 and adhesive layer 330 , as provided for by the notch 352 .

[0043] Although preferably attached to the carrier, the bezel may alternatively be attached to mounting points affixed to the prism 310 , or otherwise positioned to place the guide, or “notch” in position for a dislodging tool to be inserted above the prism face and below the microdisplay 320 .

[0044] In another embodiment, shown in FIG. 3B, a carrier 360 is roughly the same dimensions as a microdisplay 365 . A bezel 370 is then elongated to attach to a side of the carrier 360 and extend downward along the microdisplay 365 . The bezel 370 preferably includes a notch 375 for guiding a chisel, razor blade, or other dislodging tool toward the adhesive layer 380 .

[0045] In addition to providing a “notch” for the insertion of the dislodging tool, another function of the bezel 335 / 370 is to constrain the adhesive used to bond the microdisplay to the carrier. Preferably, the adhesive is constrained to a restricted area surrounding the microdisplay within the inner boundaries of the bezel. Constraining the adhesive 330 / 380 is useful in the manufacture of prism assemblies or other optical elements that use microdisplays. Also, if at any time it becomes necessary to remove the microdisplay from the prism, a sharp chisel (such as a razor blade) is inserted into the notch formed by the bezel. The notch is a space between the bezel and PBS surface that allows insertion of the chisel. Preferably, the notch locates the edge of the chisel exactly at the interface between the constrained adhesive layer and the prism face, and the microdisplay is cleaved from the prism by application of a sharp blow to the chisel.

[0046] Bezel 335 includes a guide for guiding the dislodging tool toward the notch 352 . A sloped edge 350 of bezel 335 directs a dislodging tool being inserted toward notch 352 and the interface between the prism surface 312 and adhesive layer 330 . The point of cleavage is the point where the dislodging tool 340 impacts the adhesive and breaks the seal between the microdisplay 320 and prism 310 . Preferably, the point of cleavage is the interface between the adhesive 330 and prism 310 and located opposite a side of the microdisplay having attachments or cabling for power or data transfer. In one alternative, the slope begins at a point below the carrier to just above the interface of the adhesive layer and prism surface 312 (see sloped edge 375 ).

[0047] The microdisplay attached via adhesive to an optical component is well secured from forces occurring from any origin (e.g., shipping, customer movement, etc.), and the microdisplays will maintain their registration even with the application of many different forces. However, a sharp blow applied as discussed above instantly releases the microdisplay. The present inventors have performed numerous field tests and striking the adhesive at the interface of the adhesive and the optical component, and, not only is the microdisplay released, but the adhesive is also cleanly removed (minor additional clean up using acetone, alcohol, or other cleaning material may be required in some cases).

[0048] The microdisplay, and therefore the carrier, are generally rectangular in shape. Although the present inventors prefer placing the notch on the long side of the rectangle, the point of cleavage, or notch, may be placed on either a long side, short side, or multiple sides of the rectangle. Most microdisplays include an electrical connector on one side, and, therefore, the connector side of the microdisplay is preferably not provided with a notch.

[0049] The height of the bezel may vary. The adhesive layer 330 may be contained completely within the boundaries of the bezel (as shown), or certain amounts of the adhesive may seep under part of the bezel (not shown). An amount of gap (notch height) between the bezel and prism surface 312 may be adjusted to allow more or less seepage. Seepage under the bezel is illustrated as 385 in FIG. 3B ). In either scenario, the bezel still functions to provide a guide for the dislodging tool and to constrain the adhesive.

[0050] Note that the disclosed package configuration is consistent with the inclusion of other possibly desired optical elements such as a compensating waveplate and/or a light mask. The exact number, type, and configuration of other optical elements will depend on engineering considerations for a particular design. A more complex package assembly is illustrated in FIG. 4 , which includes a taller bezel 400 , including a notch part 410 , and additional optical elements. The additional optical elements include, for example, a black mask 415 , spacer glass 420 , and quarter waveplate 425 . Other optical elements or devices may be arranged similarly or in various combinations depending on the specific application. The number and arrangement of optical elements can become quite extensive and is referred to as an optical stack. Regardless of the number, type, or arrangement of components in the optical stack, in the thus far described embodiments, the bezel acts as a guide to place the dislodging tool at the interface between prism surface 312 and the adhesive layer 330 .

[0051] The black mask is a light shield that has a opening cut out for the active matrix array (or liquid crystal elements) of the microdisplay 320 . The black mask acts as an optical shield to prevents excess light from contacting any of the light sensitive transistors at or near the exposed active matrix array of the microdisplay 320 . The black mask protects the silicon above and beyond protection afforded by other thin films in the silicon that protect the transistors in the silicon and allows light to interact with liquid crystal elements.

[0052] FIG. 5 is an illustration of a package configuration that includes features that reduce stress. As seen in FIG. 5 , an air gap 500 exists between a front surface of the microdisplay 320 and the face of the prism (prism surface 312 ). The air gap 500 physically decouples the microdisplay from the prism and prevents the build up and transmission of stress. The air gap 500 also acts as a “thermal insulator” and moderates any temperature increase of the microdisplay caused by the temperature of the PBS 300 or other environmental factors that might generate heat. This minimizes any physical distortion that may be generated within the microdisplay because of temperature changes or differences in thermal expansion of the microdisplay 320 (or any of its parts) and the PBS 300 .

[0053] A bezel 510 is glued (via adhesive 520 ) to the face of the prism (e.g., prism surface 312 ). The adhesive 520 holds the bezel and attached package and, hence, the microdisplay, firmly in place maintaining registration between the three microdisplays (registration refers to aligning the pixel arrays of each microdisplay—e.g., pixel 1 , 1 of each microdisplay process a same pixel output at position 1 , 1 in the output image). In the previously described embodiments, the microdisplay 320 was glued to the prism surface 312 , which also maintained registration of the microdisplay 320 with the other microdisplays. Preferably, the glued microdisplay 320 is part of a multi microdisplay device, such as a light engine, but could be part of a different device, in which case the microdisplay (or other optical or electronic device) is glued in a position that maintains a registration needed for that different device. In this example embodiment, the package includes a carrier 325 and microdisplay 550 , which, because of the air gap 500 , does not contact the prism surface.

[0054] In one embodiment, the height of the bezel is less than that of the upper surface of the microdisplay (note bezel height relative to the microdisplay in FIG. 5 ). However, other bezel heights may be utilized depending on a particular application or arrangement of additional optical elements (note bezel height in FIG. 6 extends below the upper surface of the microdisplay).

[0055] The package, including the carrier, bezel, and microdisplay is mounted to the prism 310 by holding the package in a precise position that is registered with other microdisplays or required lightpaths of a device being constructed, and then adhesive is applied to the bezel and prism surface 312 . During the process of mounting the package to the prism, the package is held in the precise position by a precise adjusting mechanism, such as a multi-axis clamp having a fine adjustment (e.g., micrometer adjustment) for each axis.

[0056] The present invention includes the method for mounting the package. As a first step, the upper surface of the microdisplay is brought into direct contact with the face (e.g., surface 312 ) of the prism. This establishes proper tip and yaw orientation of the microdisplay with respect to the face of the prism. The microdisplay is then backed off from the prism to establish the air gap. The distance backed off is carefully controlled by the precise adjusting mechanism (e.g., using a back-off micrometer adjustment) and is typically quite small, on the order of mils. The adhesive 520 is placed in a bead between the face of the prism and the edges of the bezel 510 .

[0057] In the above disclosed air gap configuration it is desirable to include an anti-reflection coating on the upper surface of the microdisplay and on the facing surface of the prism (e.g., AR coatings 560 ).

[0058] The embodiment of FIG. 5 may also be extended to include multiple other optical elements in an optical stack. FIG. 6 is an illustration of a more complex optical stack arranged in an air gap embodiment of the present invention. The optical stack in FIG. 6 includes an air gap 673 from the upper surface of the microdisplay 650 to a black mask 685 . Another air gap 675 extends from the surface 312 of prism 300 up through an opening 680 of black mask 685 and meets with air gap 673 . The black mask 685 acts as a light shield to protect transistors, exposed silicon, and/or other components other than the parts of the microdisplay that are intended to be exposed to the light paths through the prisms and optical stack. Note that an air gaps exists on either side of the black mask (the combined air gaps 673 and air gap 675 ) which mechanically and thermally isolate the black mask from both the microdisplay and the prism. In one embodiment, the black mask 685 is held in position by an adhesive bead or drops of adhesive cured on each of the black mask and the bezel. In other embodiments, insulating stubs protrude (e.g., from the prism face 312 or the microdisplay 650 ) and attach to the black mask. Any other method of securing the black mask to maintain its position is appropriate.

[0059] A quarter waveplate or other optical elements may also be included with or substituted for the black mask in the optical stack. FIG. 7 is an example of a microdisplay package 700 that includes an optical stack having a quarter waveplate 715 and a black mask 705 . Not illustrated in FIG. 7 is a cover glass on the outer surface of the quarter waveplate 715 . Such a cover glass would become the “top” layer in the optical stack (situated between the quarter waveplate 715 and the air gap 700 ). The desirability of including the extra cover glass derives in part from the fact that it is easier to apply an anti-reflection coating to glass.

[0060] Another embodiment of the present invention is illustrated in FIG. 8 . In this embodiment, an index matching fluid has been injected through a small gap or hole (not shown). The index matching fluid provides a liquid coupling that fills the air gap(s) within the microdisplay package 800 and between the microdisplay package and prism 310 .

[0061] In one embodiment, the fill hole is closed off using an adhesive after the filling process is complete. The small gap may be a small hole in the bezel 810 , or a tube through the adhesive 820 . Any opening that provides access to the air gap may be utilized. The hole, tube, or gap is filled with adhesive or a plug is inserted to seal in the liquid (index matching fluid).

[0062] The use of the index matching fluid greatly reduces or eliminates the need for the anti reflection (AR) layers on the prism, microdisplay, and/or other elements of the optical stack. The liquid coupling will also as effective in not transmitting or sustaining the build up of stress. The liquid coupling method is compatible with the inclusion of a black mask and/or waveplates in an optical stack.

[0063] Preferably, the index matching fluid has an index of refraction that matches an index of refraction of the optical pieces which it couples. However, in most embodiments, the coupled optical pieces will have different indexes of refraction, therefore, the preferred index of refraction of the coupling fluid is a s close as possible to an average index of refraction of the coupled optical pieces. For example, in FIG. 8 , the index of refraction of the index matching fluid is as close as possible to the index of refraction (ir) of prism 310 plus the index of refraction of an optical surface of the microdisplay 850 divided by 2 (e.g., (ir 310 +ir 850 )/2). The selected index of refraction for any of the optical pieces and/or fluids will also be varied by their availability in the desired properties.

[0064] Note that it is preferable to provide accommodations to allow for the differential expansion of the index matching fluid as compared to the package “container”. Various possible accommodations are discussed in Detro et al., U.S. Provisional Patent Application Serial No. 60/356,207, entitled “Means to Accommodate Expansion in Liquid Coupled Prism Assemblies.” The described accommodations can each be applied to the microdisplay package 800 . In one embodiment, an air bubble is trapped inside the perimeter of the bezel 810 and adhesive 820 . The trapped air bubble is preferably a size such that it is lodged out of the lightpaths that are incident with the microdisplay. In one embodiment, the air bubble is lodged between the microdisplay 850 and bezel 810 . Preferably, an orientation of the package helps maintain the air bubble out of the light paths.

[0065] In another embodiment, an air bladder is inserted in the package. One location for placing the air bladder is between the microdisplay 850 and bezel 810 . The bezel 810 may be extended at one part to accommodate inclusion of an air bladder, and the air bladder may be fixed to the bezel (preventing it from drifting into the microdisplay incident lightpath).

[0066] In another embodiment, a flexible diaphragm is placed over an opening in the microdisplay package 800 . The opening leads to the index matching fluid and is sealed by the diaphragm which flexes with expansion and contraction of the index matching fluid. The opening is preferably located on the bezel, but may be paced in any location that provides access to the index matching fluid.

[0067] In yet another embodiment, a tube is inserted into the microdisplay package 800 . Preferably, the tube is inserted through a hole drilled in the bezel. The tube is open at the end inserted into the microdisplay and sealed at the outer end. An air bubble is maintained in the tube which expands or contracts with the index matching fluid.

[0068] In still yet another embodiment, a tube with a piston is inserted into the microdisplay package 800 . Again, the tube may be inserted through a hole in the bezel, or may be otherwise accommodated by a cut out in the bezel, inserted through the adhesive, or a combination of the above. Any method of inserting the tubes is acceptable, so long as the open end is in contact with the index matching fluid. In this embodiment, air is not maintained in the tube, and the piston moves out or in to accommodate expansion and contraction of the index matching fluid. The tube may include stops to prevent the piston from falling out of the tube. Stops may be placed on both ends of the tube.

[0069] FIG. 9 is an illustration of a combined air gap and direct mounting of a microdisplay package 900 including an optical stack 920 according to an embodiment of the present invention.

[0070] The microdisplay package includes a carrier 960 , bezel 965 , and bottom cover glass 940 . The microdisplay package 900 holds and encloses the microdisplay 950 . The optical stack 920 includes a cover glass 925 of a microdisplay 950 , black mask 930 , air gap 935 , bottom cover glass 940 , quarter waveplate 945 , and top cover glass 955 . Again the optical stack may include additional or less components, or be arranged in a different order depending on the specific application to which the optical stack is being applied. In this example embodiment, the optical stack includes components that are shared with the microdisplay package 900 (e.g., bottom cover glass 940 is part of the package and the optical stack). In addition, the bezel 965 and quarter waveplate provide an overhang that helps guide a dislodging tool toward the adhesive/prism 910 interface for removal of the package.

[0071] In another embodiment, a second bezel extends from the quarter waveplate 945 toward surface 912 to provide additional guidance (e.g., see bezel 400 & notch 410 shown in FIG. 4 ). In another embodiment, the second bezel is installed and adhesive is utilized to seal the bezel to the prism surface 912 and liquid (e.g., optical coupling fluid) is placed between the top cover glass 955 and the prism surface 912 . Any and all methods of attaching or coupling a microdisplay package to a prism surface as described elsewhere herein are also applicable to this and other embodiments or variations of the present invention.

[0072] In FIG. 9 , the optical stack includes an air gap 930 , which may also be replaced with an optical coupling fluid (and thereby removing or greatly reducing any need to provide anti-reflection coatings on the glass surfaces).

[0073] FIG. 9 represents an innovative LCoS direct mounting system that takes advantage of the best design features discussed herein. Primarily, the embodiment of FIG. 9 provides for each of the advantages associated with a thermal insulation layer, direct mounting, ease of decoupling, cooling, and a lack of exposed surfaces.

[0074] Although direct mounted, the embodiment of FIG. 9 transmits little or no mechanical stresses from the prism, bezel, or other components that are either mounted or in contact with other parts. The bezel is not connected to the microdisplay so no stress is transmitted directly from the bezel to the microdisplay.

[0075] The air gap 935 provides a very efficient thermal insulator so that heat buildup in the prisms 910 , 905 , et al., is effectively isolated from the microdisplay 950 . A greater surface area of the package around the microdisplay (including carrier 960 ) helps dissipate any heat that is being conducted in a path toward the microdisplay (heat and stress must first be transmitted up to the carrier and then down to the microdisplay, which provides both physical and thermal isolation for the microdisplay.

[0076] One known problem in microdisplay based projectors is that large amounts of dust and other impurities can become lodged or settle on the optical surfaces of prisms and microdisplays. However, in the present invention, and particularly the package 900 , all optical surfaces of the microdisplay and prism/microdisplay interfaces are completely enclosed. Dust and other impurities are prevented from reaching the microdisplay and other optical surfaces.

[0077] One of the largest problems with current air gap mounting techniques (e.g., see FIG. 2 ) is that forces or vibrations encountered during manufacture, shipping, and/or installation causes the microdisplays to move out of registration. If the microdisplays move more than 2 microns, they are out of registration causing costly service to re-align. Direct mounting of the microdisplay package, such as that illustrated in FIG. 9 , maintains registration of the microdisplay under a wide range of forces from virtually any source. Still further, because the adhesive layer may be removed via a specific force from a chisel, razor blade, or other dislodging tool, the microdisplay may also be easily removed for repair or replacement. In the embodiment of FIG., 9 , removal is best performed by placing a razor blade on the surface 912 with a sharp edge contacting the adhesive. A quick blow (or tap) to the razor blade parallel to the plane of surface 912 causes the adhesive to cleave at the adhesive/surface 912 interface, removing the microdisplay package from surface 912 .

[0078] Although the present invention has been described herein with reference to microdisplays mounted on a prism, the devices and processes of the present invention may be applied to the mounting of other optical or electronic devices.

[0079] In describing preferred embodiments of the present invention illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the present invention is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents which operate in a similar manner. For example, when describing index matching fluid, any other equivalent product, such as a coupling fluids, mineral oils, or other products having an equivalent function or capability, whether or not listed herein, may be substituted therewith. Furthermore, the inventors recognize that newly developed technologies not now known may also be substituted for the described parts and still not depart from the scope of the present invention. All other described items, including, but not limited to microdisplays, prisms, optical elements, masks, adhesives, positioning mechanisms, fluids, etc., should also be consider in light of any and all available equivalents.

[0080] Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.