Yamaguchi, Hideo (Matsumoto-shi, JP)
Hashizume, Hidetoshi (Hotaka-machi, JP)
Fujisawa, Shohei (Matsumoto-shi, JP)
Iinuma, Kazuyuki (Hotaka-machi, JP)
2. The optical component casing according to claim 1, wherein the casing body is formed by sheet metal processing.
3. The optical component casing according to claim 1 or 2, wherein the plurality of positioning members include a parallel arrangement positioning member that abuts on the optical component arranged along an inner side of the casing body to position the optical component at the predetermined position on the illumination optical axis of the light beam irradiated by the light source.
4. The optical component casing according to claim 3, wherein the parallel arrangement positioning member has a plurality of pins inserted to the plurality of holes to abut on the optical component.
5. The optical component casing according to claim 4, wherein the parallel arrangement positioning member includes a plate body integrating the plurality of pins.
6. The optical component casing according to any one of claims 1 to 5, wherein the plurality of positioning members include orthogonal arrangement positioning members each of which abuts on the optical component housed in the casing body in a manner orthogonal to the illumination optical axis of the light beam irradiated by the light source to position the optical component at the predetermined position on the illumination optical axis of the light beam irradiated by the light source.
7. The optical component casing according to claim 6, wherein the orthogonal arrangement positioning member has a groove having a V-shaped cross-section so that the groove abuts on an outer periphery of the optical component.
8. The optical component casing according to any one of claims 1 to 7, wherein a support portion for supporting the positioning member is formed at the hole.
9. The optical component casing according to claim 8, wherein the hole is formed by cutting and folding a part of a lateral side of the casing body, wherein the cut and folded part of the lateral side serves as the support portion.
10. The optical component casing according to any one of claims 1 to 9, further comprising: a pair of plate members opposite to both ends of the optical component housed in an inclined manner relative to the lateral side of the casing body, wherein the plurality of positioning members include an inclined arrangement positioning member that includes spacers respectively interposed between the both ends of the optical component and the plate members to position the optical component at the predetermined position on the illumination optical axis of the light beam irradiated by the light source by way of the spacers.
11. The optical component casing according to claim 10, wherein the inclined arrangement positioning member includes the spacers, a mount fixed on the bottom side of the casing body and the pair of plate members vertically provided on the mount.
12. The optical component casing according to claim 10 or 1 1, wherein each part of the pair of plate members is cut and folded toward the other plate member, wherein the cut and folded part of the plate member serves as a support portion for supporting the spacer.
13. The optical component casing according to any one of claims 10 to 12, wherein the spacer has a face slanted along an inclined direction of the optical component.
14. An optical component casing with an illumination optical axis of light beam irradiated by a light source being set therein, in which a plurality of optical components are housed and arranged at predetermined positions on the illumination optical axis, the optical component casing comprising: a casing body having a hole penetrating toward the inside thereof and support portions for supporting a group of the plurality of optical components; and a plurality of positioning members for positioning the rest of the plurality of optical components at predetermined positions in the optical component casing, wherein the plurality of positioning members are inserted to the holes to abut on the optical components so that the rest of the optical components are positioned at the predetermined positions on the illumination optical axis of the light beam irradiated by the light source, wherein the group of the optical components are held by the support portions while being positioned at the predetermined positions on the illumination optical axis of the light beam irradiated by the light source, wherein each one side of the group of the optical components is fixed on each one side of the support portions.
15. The optical component casing according to claim 14, wherein a groove is formed on each of the support portions at a position abutting the one side of the group of the optical components to inject an adhesive for fixing the group of the optical components.
16. The optical component casing according to claim 15, wherein the groove is formed in an approximately planarly-viewed straight line extending from a first side of the support portion to a second side opposite to the first side so that an outflow of the adhesive from the first side to the second side opposite to the first side is restricted by a terminal on the second side.
17. An optical component casing with an illumination optical axis of light beam irradiated by a light source being set therein, in which a plurality of optical components are housed and arranged at predetermined positions on the illumination optical axis, the optical component casing comprising: a plurality of support portions formed on an inner side of the optical component casing for respectively supporting the plurality of optical components, wherein the plurality of optical components are respectively held by the plurality of support portions while being positioned at the predetermined positions on the illumination optical axis of the light beam irradiated by the light source, wherein each one side of the plurality of optical components is respectively fixed on each one side of the plurality of support portions.
18. The optical component casing according to claim 17, wherein at least one of the support portions is formed in a profile having a V-shaped cross-section to sandwich and support both sides of the optical component, wherein each inner side of the support portions is fixed on at least one of the both sides of the optical component.
19. The optical component casing according to claim 17 or 18, wherein at least one of the plurality of support portions projects from the inner side of the optical component casing to support the optical component arranged along the inner side at a projected tip end thereof, wherein the tip end of the support portion is fixed on the one side of the optical component.
20. The optical component casing according to claim 19, wherein the optical component casing is a synthetic resin molding product having a frame-shaped hole formed on the inner side of the optical component casing to planarly surround the support portion.
21. The optical component casing according to any one of claims 18 to 20, wherein a groove for an adhesive for fixing the optical component to be injected is formed on the support portion at a position abutting on the optical component.
22. An optical component casing with an illumination optical axis of light beam irradiated by a light source being set therein, in which a plurality of optical components are housed and arranged at predetermined positions on the illumination optical axis, wherein a plurality of holes into which each part of positioning jigs for positioning the plurality of optical components at the designed predetermined positions can be inserted are formed on a side of the optical component casing.
23. A projector comprising: an optical component casing according to any one of claims 1 to 22; a plurality of optical components housed and arranged in the optical component casing to form an optical image in accordance with image information; and a projection optical device for projecting the optical image formed by the plurality of optical components in an enlarged manner.
TECHNICAL FIELD
The present invention relates to an optical component casing and a projector.
BACKGROUND ART
Conventionally, a projector that makes an optical modulator to modulate a light beam irradiated by a light source in accordance with image information and form an optical image and projects the optical image in an enlarged manner has been known (for example, refer to Patent Publication 1 (JP2002-31843A)).
The projector includes optical components such as a lens for superposing the light beam irradiated by the light source on an image formation area of the optical modulator, a dichroic mirror for separating the light beam irradiated by the light source into three color lights (R, G and B) and a reflection mirror for conducting the light beam irradiated by the light source to the optical modulator, and an optical component casing, in which the optical components are housed and arranged at predetermined positions on an illumination optical axis of the light beam irradiated by the light source.
The optical component casing, which is a synthetic resin molding product manufactured by molding such as injection molding, has a groove formed on an inner side thereof to serve as an external position reference face of the optical component so that the optical component slides and fits to the groove.
However, the groove formed on the inner side of the optical component casing requires to be highly accurately formed to house and arrange the respective optical components at predetermined positions on the illumination optical axis of the light beam irradiated by the light source. Accordingly, since a molding die for the optical component casing needs to be a complicated profile and to be highly accurately manufactured, manufacturing of the optical component casing may be difficult while the production cost thereof may be increased.
An object of the present invention is to provide an optical component casing and a projector that can reduce the production cost and can easily be manufactured.
DISCLOSURE OF THE INVENTION
An optical component casing according to an aspect of the present invention with an illumination optical axis of light beam irradiated by a light source being set therein, in which a plurality of optical components are housed and arranged at predetermined positions on the illumination optical axis, the optical component casing includes: a casing body having a plurality of holes penetrating toward the inside thereof, in which the plurality of optical components are housed and arranged therein; and a plurality of positioning members for positioning the plurality of optical components at the predetermined positions in the casing body, in which the plurality of positioning members are inserted to the plurality of holes to abut on the optical components so that the plurality of optical components are positioned at the predetermined positions on the illumination optical axis of the light beam irradiated by the light source.
The casing body may be any profile as long as the plurality of optical components can be housed and arranged therein. For instance, the casing body may be a container structure or a hollow structure.
Further, the casing body may be a synthetic resin molding product manufactured by molding such as injection molding in the same manner as the conventional art, a structure formed by sheet metal processing, or a structure formed by BMC (Bulk Molding Compound).
For instance, the plurality of holes include an opening of the container when the casing body is formed in a container structure.
With this arrangement, the optical component casing includes the casing body and the plurality of positioning members. The plurality of positioning members are inserted from the outside of the casing body to the inside thereof through the holes to abut on the optical components. Accordingly, after the optical components are shifted and the positions are adjusted, the optical components can be easily positioned at the predetermined positions on the illumination optical axis of the light beam irradiated by the light source. Thus, the plurality of optical components can be housed and arranged at the proper positions in the casing body by way of the plurality of positioning members without highly accurately manufacturing the casing body, thus easily manufacturing the optical component casing and reducing the production cost thereof.
Further, since the positioning members abut on the optical components to position the optical components at the predetermined positions in the casing body, when the optical components are fixed in the casing body together with the positioning members, a member such as a holder frame for holding the optical components can be omitted, thereby reducing the production cost of the optical unit when the optical unit including the optical components and the optical component casing is manufactured.
Preferably, in the above optical component casing, the casing body is formed by sheet metal processing.
According to this arrangement, since the casing body is formed by sheet metal processing, the casing body can further easily be manufactured and the production cost of the optical component casing can further be reduced as compared to the conventional optical component casing which is a synthetic resin molding product which has an external position reference face therein and requires highly accurate manufacturing.
Since the casing body is made of metal, heat generated at the plurality of optical components due to irradiation of the light beam irradiated by the light source can be radiated to the casing body, cooling efficiency of the optical components can be enhanced.
Preferably, in the above optical component casing, the plurality of positioning members include a parallel arrangement positioning member that abuts on the optical component arranged along an inner side of the casing body to position the optical component at the predetermined position on the illumination optical axis of the light beam irradiated by the light source.
For example, the optical component arranged along the inner side of the casing body is a full reflection mirror for conducting the light beam irradiated by the light source to a predetermined position.
With this arrangement, for example, the parallel arrangement positioning member is inserted from the outside of the casing body to the inside thereof through the hole to abut on a back side of the optical component such as the full reflection mirror or an end of the optical component such as the full reflection mirror so that the optical component can easily positioned at the predetermined position on the illumination optical axis of the light beam irradiated by the light source, after the optical component is shifted and the position thereof is adjusted. When the optical component is fixed on the casing body together with the parallel arrangement positioning member, the light beam irradiated by the light source can be prevented from being shielded due to the parallel arrangement positioning member.
Preferably, in the above optical component casing, the parallel arrangement positioning member has a plurality of pins inserted to the plurality of holes to abut on the optical component.
With this arrangement, when the plurality of pins are shifted to shift the optical component such as the full reflection mirror for positioning at the predetermined position with the plurality of pins inserted from the outside of the casing body to the inside thereof and abutting on the back side of the optical component such as the full reflection mirror or the end of the optical component such as the full reflection mirror, the optical component such as the full reflection mirror can be easily positioned at the predetermined position by shifting the plurality of pins to the inside or the outside of the casing body.
Further, when the optical component such as the full reflection mirror is fixed on the casing body together with the plurality of pins, the plurality of pins reduce an external force so that the position of the optical component such as the full reflection mirror can be fixed on the casing body without displacement.
Preferably, in the above optical component casing, the parallel arrangement positioning member includes a plate body integrating the plurality of pins.
With this arrangement, since the parallel positioning member includes the plate body, for instance, when the optical component such as the full reflection mirror is shifted by shifting the plurality of pins to position at the predetermined position, each pin can be shifted at once only by shifting the plate body so that the optical component such as the full reflection mirror is positioned at the predetermined position. Accordingly, the optical component can further be easily positioned.
Further, since the plurality of pins are integrated by the plate body and the positions of the plurality of pins are relatively fixed, when the optical component such as the full reflection mirror is fixed on the casing body together with the parallel arrangement positioning member, the position of the optical component such as the full reflection mirror can further preferably be fixed on the casing body.
Further, when the optical component is replaced etc., the plurality of pins can be removed at once without a cumbersome work of removing the plurality of pins one by one, thus enhancing reworkability of the optical component.
Preferably, in the above optical component casing, the plurality of positioning members include orthogonal arrangement positioning members each of which abuts on the optical component housed in the casing body in a manner orthogonal to the illumination optical axis of the light beam irradiated by the light source to position the optical component at the predetermined position on the illumination optical axis of the light beam irradiated by the light source.
For example, the optical component housed in the casing body to be orthogonal to the illumination optical axis of the light beam irradiated by the light source may be a light beam separating optical element for separating the light beam irradiated by the light source, a focusing optical element for focusing the light beam irradiated by the light source at a predetermined position, or the like.
With this arrangement, for example, the orthogonal arrangement positioning member is inserted from the outside of the casing body to the inside thereof through the hole to abut on the outer periphery of the optical component such as the light beam separating optical element or the focusing optical element so that the optical component such as the light beam separating optical element or the focusing optical element can easily positioned at the predetermined position on the illumination optical axis of the light beam irradiated by the light source by way of the orthogonal arrangement positioning member, after the optical component is shifted and the position thereof is adjusted.
Preferably, in the above optical component casing, the orthogonal arrangement positioning member has a groove having a V-shaped cross-section so that the groove abuts on an outer periphery of the optical component.
With this arrangement, since the orthogonal arrangement positioning member has the groove having a V-shaped cross-section, the orthogonal arrangement positioning member can securely abut on the outer periphery of the optical component. Accordingly, the optical component can accurately be positioned by the orthogonal arrangement positioning member.
Further, since the groove of the orthogonal arrangement positioning member abuts on the outer periphery of the optical component so that the optical component is positioned at the predetermined position in the casing body, when the optical component is fixed on the casing body together with the orthogonal arrangement positioning member, the orthogonal arrangement positioning member reduces an external force so that the position of the optical component can be fixed on the casing body without displacement.
Preferably, in the above optical component casing, a support portion for supporting the positioning member is formed at the hole.
With this arrangement, since the support portion is formed at the hole, the positioning member can smoothly be shifted to accurately position the optical component.
Further, when the optical component is fixed on the casing body together with the positioning member, the position of the optical component can further securely be fixed by the positioning member and the support portion for supporting the positioning member.
Preferably, in the above optical component casing, the hole is formed by cutting and folding a part of a lateral side of the casing body, and the cut and folded part of the lateral side serves as the support portion.
With this arrangement, since the hole and the support portion are formed by cutting and folding the part of the lateral side of the casing body, the hole and the support portion can easily be formed, and consequently, the optical component casing can further easily be manufactured and the production cost thereof can be reduced.
Preferably, the above optical component casing further includes: a pair of plate members opposite to both ends of the optical component housed in an inclined manner relative to the lateral side of the casing body, in which the plurality of positioning members include an inclined arrangement positioning member that includes spacers respectively interposed between the both ends of the optical component and the plate members to position the optical component at the predetermined position on the illumination optical axis of the light beam irradiated by the light source by way of the spacers.
For example, the optical component housed in an inclined manner relative to the lateral side of the casing body may be a color-separating optical element for separating the light beam irradiated by the light source into a plurality of color lights.
Further, the lateral side of the casing body may be a plate member, or components of the casing body except for the lateral side may be plate members.
With this arrangement, since the inclined arrangement positioning member includes the spacer, the optical component such as the color-separating optical element can easily be positioned at the predetermined position on the illumination optical axis of the light beam irradiated by the light source, by interposing the spacer between the end of the optical component such as the color-separating optical element and the plate member, after the optical component is shifted and the position thereof is adjusted.
Further, since the spacer of the inclined arrangement member is interposed between the end of the optical component such as the color-separating optical element and the plate member to position the optical component at the predetermined position in the casing body, when the optical component is fixed in the casing body together with the spacer, a member such as a holder frame for holding the optical components such as the color-separating optical element can be omitted, thereby reducing the production cost of the optical unit when the optical unit including the optical components and the optical component casing is manufactured.
Preferably, in the above optical component casing, the inclined arrangement positioning member includes the spacers, a mount fixed on the bottom side of the casing body and the pair of plate members vertically provided on the mount.
With this arrangement, since the inclined arrangement positioning member includes the spacer, the mount and the plate member, the lateral side of the casing body is not required to be formed as a plate member. In other words, even when the profile of the optical component such as the color-separating optical element is changed, the profile of the casing body is not necessary to be changed, but the plate member of the inclined arrangement positioning member can correspond by changing the adjacent distance thereof.
Preferably, in the above optical component casing, each part of the pair of plate members is cut and folded toward the other plate member, and the cut and folded part of the plate member serves as a support portion for supporting the spacer.
With this arrangement, since the spacer is supported by the support portion, the spacer can smoothly be shifted to accurately position the optical component.
Further, when the optical component is fixed on the casing body together with the spacer, the position of the optical component such as the color-separating optical element can securely be fixed by the spacer and the support portion for supporting the spacer.
Preferably, in the above optical component casing, the spacer has a face slanted along an inclined direction of the optical component.
With this arrangement, since the spacer has the slanted face, the spacer can securely abuts on the end of the optical component. Accordingly, the optical component can accurately be positioned by the spacer.
Further, since the optical component is positioned at the predetermined position in the casing body with the slanted face of the spacer abutting on the end of the optical component, when the optical component is fixed on the casing body together with the spacer, the fixing state of the optical component can securely be maintained on the casing body.
An optical component casing according to another aspect of the present invention with an illumination optical axis of light beam irradiated by a light source being set therein, in which a plurality of optical components are housed and arranged at predetermined positions on the illumination optical axis, the optical component casing includes: a casing body having a hole penetrating toward the inside thereof and support portions for supporting a group of the plurality of optical components; and a plurality of positioning members for positioning the rest of the plurality of optical components at predetermined positions in the optical component casing, in which the plurality of positioning members are inserted to the holes to abut on the optical components so that the rest of the optical components are positioned at the predetermined positions on the illumination optical axis of the light beam irradiated by the light source, in which the group of the optical components are held by the support portions while being positioned at the predetermined positions on the illumination optical axis of the light beam irradiated by the light source, and in which each one side of the group of the optical components is fixed on each one side of the support portions.
The casing body may be any profile as long as the plurality of optical components can be housed and arranged therein. For instance, the casing body may be a container structure or a hollow structure in the same manner as the above-described casing body of the optical component casing. Further, for example, the casing body may be a synthetic resin molding product manufactured by molding such as injection molding in the same manner as the conventional art, a structure formed by sheet metal processing, or a structure formed by BMC (Bulk Molding Compound).
With this arrangement, a group of the plurality of optical components are fixed on the support portions formed on the inner side of the casing body while positioned at the predetermined positions on the illumination optical axis of the light beam irradiated by the light source. Accordingly, the manufacturing accuracy of the some of the optical components need not to be so high. Further, the rest of the optical components of the plurality of optical components are positioned at the predetermined positions by way of the positioning members inserted from the outside of the casing body to the inside thereof. Accordingly, the casing body may not highly accurately be manufactured, thus easily manufacturing the optical component casing and reducing the production cost thereof.
Further, when the group of the optical components are directly fixed on the support portions and the rest of the optical components are fixed in the casing body together with the positioning members, a member such as a holder frame for holding the plurality of optical components can be omitted, thereby reducing the production cost of the optical unit when the optical unit is manufactured.
For instance, since the positioning members are used only for the rest of the optical components requiring relatively high positioning accuracy, the number of the positioning members may be minimized, thus reducing the weight and the production cost of the optical component casing based upon the omission of the members. Further, when the optical unit is manufactured, the placement process of the positioning member can be simplified, thus quickly manufacturing the optical unit and reducing the production cost thereof.
Preferably, in the above optical component casing, a groove is formed on each of the support portions at a position abutting the one side of the group of the optical components to inject an adhesive for fixing the group of the optical components.
With this arrangement, since the groove for injecting the adhesive is formed on the support portion, the adhesive can easily be injected between the support portion and the group of the optical components. When the adhesive is applied between the support portion and the group of the optical components, the group of the optical components can be prevented from the adhesive unnecessarily adhering. For instance, even when the gap between the support portion and the group of the optical components becomes narrow due to manufacturing error of the casing body, the adhesive can easily be injected between the support portions and the group of the optical components.
Preferably, in the above optical component casing, the groove is formed in an approximately planarly-viewed straight line extending from a first side of the support portion to a second side opposite to the first side so that an outflow of the adhesive from the first side to the second side opposite to the first side is restricted by a terminal on the second side.
Restricting the outflow of the adhesive from the first side to the second side opposite to the first side by the terminal opposite to the first side means that the groove does not penetrate from the first side to the second side opposite to the first side.
With this arrangement, since the groove does not penetrate from the first side to the second side opposite to the first side, the adhesive does not leak from the second side opposite to the first side when the adhesive is injected between the support portions and the group of the optical components, thus preventing the casing body from the adhesive unnecessarily adhering.
An optical component casing according to still another aspect of the present invention with an illumination optical axis of light beam irradiated by a light source being set therein, in which a plurality of optical components are housed and arranged at predetermined positions on the illumination optical axis, the optical component casing includes: a plurality of support portions formed on an inner side of the optical component casing for respectively supporting the plurality of optical components, in which the plurality of optical components are respectively held by the plurality of support portions while being positioned at the predetermined positions on the illumination optical axis of the light beam irradiated by the light source, and in which each one side of the plurality of optical components is respectively fixed on each one side of the plurality of support portions.
The optical component casing may be any profile as long as the plurality of optical components can be housed and arranged therein. For instance, the casing body may be a container structure or a hollow structure in the same manner as the above-described casing body of the optical component casing. Further, for example, the casing body may be a synthetic resin molding product manufactured by molding such as injection molding in the same manner as the conventional art, a structure formed by sheet metal processing, or a structure formed by BMC (Bulk Molding Compound).
With this arrangement, the plurality of optical components are fixed on the plurality of support portions formed on the inner side of the optical component casing with the optical components positioned at the predetermined positions on the illumination optical axis of the light beam irradiated by the light source device. Thus, the plurality of optical components can be housed and arranged at the proper positions in the casing body without highly accurately manufacturing the optical component casing, thus easily manufacturing the optical component casing and reducing the production cost thereof.
Further, as compared to the above-described optical component casing, the positioning member can be omitted so that the production cost of the optical component casing can further be reduced as well as the weight of the optical component casing can be reduced, and consequently, the weight of the optical unit can be reduced. Further, when the optical unit is manufactured, the placement process of the positioning member can be simplified, thus quickly manufacturing the optical unit and reducing the production cost thereof.
Preferably, in the above optical component casing, at least one of the support portions is formed in a profile having a V-shaped cross-section to sandwich and support both sides of the optical component, and each inner side of the support portions is fixed on at least one of the both sides of the optical component.
With this arrangement, since at least one of the plurality of support portions are formed in a profile having a V-shaped cross-section and the optical component is fixed on the inner side thereof, the optical component can preferably be supported, and the support portion reduces an external force so that the position of the optical component can be fixed on the optical component casing without displacement.
Preferably, in the above optical component casing, at least one of the plurality of support portions projects from the inner side of the optical component casing to support the optical component arranged along the inner side at a projected tip end thereof, and the tip end of the support portion is fixed on the one side of the optical component.
For example, the optical component arranged along the inner side of the optical component casing may be a full reflection mirror for conducting the light beam irradiated by the light source to a predetermined position.
With this arrangement, at least one of the plurality of support portions projects from the inner side of the optical component casing. For example, the back side of the optical component such as the full reflection mirror is fixed on the tip end of the support portion. Accordingly, a gap with the dimension of the support portion projecting is formed between the inner side of the optical component casing and the back side of the optical component such as the full reflection mirror. Thus, when the optical component such as the full reflection mirror is replaced, the optical component such as the full reflection mirror can easily be removed from the optical component casing by inserting a tip end of a driver etc. into the gap, thereby enhancing reworkability of the optical component.
Preferably, in the above optical component casing, the optical component casing is a synthetic resin molding product having a frame-shaped hole formed on the inner side of the optical component casing to planarly surround the support portion.
For instance, the hole may be continuously formed in a frame-shape, or formed in a frame-shape though not being continued.
With this arrangement, since the optical component casing is a synthetic resin molding product and the frame-shaped hole is formed on the inner side of the optical component casing, the part of the inner side, where the support portion is formed, is likely to be broken from the optical component casing. Accordingly, when the optical component such as the full reflection mirror bonded to the tip end of the support portion by the adhesive is removed from the optical component casing, even when the adhesion is adhered on the tip end, the adhesive would not be remained in the optical component casing by breaking the part of the inner side where the support portion is formed. Thus, the optical component casing can be recycled.
Preferably, in the above optical component casing, a groove for an adhesive for fixing the optical component to be injected is formed on the support portion at a position abutting on the optical component.
With this arrangement, since the groove for injecting the adhesive is formed on the support portion, the adhesive can easily be injected between the support portion and the optical component. When the adhesive is applied between the support portion and the optical components, the optical components can be prevented from the adhesive unnecessarily adhering. For instance, even when the gap between the support portion and the optical component becomes narrow due to manufacturing error of the optical component casing, the adhesive can easily be injected between the support portion and the optical component.
An optical component casing according to further aspect of the present invention with an illumination optical axis of light beam irradiated by a light source being set therein, in which a plurality of optical components are housed and arranged at predetermined positions on the illumination optical axis, a plurality of holes into which each part of positioning jigs for positioning the plurality of optical components at the designed predetermined positions can be inserted are formed on a side of the optical component casing.
The optical component casing may be any profile as long as the plurality of optical components can be housed and arranged therein. For instance, the casing body may be a container structure or a hollow structure in the same manner as the above-described casing body of the optical component casing. Further, for example, the casing body may be a synthetic resin molding product manufactured by molding such as injection molding in the same manner as the conventional art, a structure formed by sheet metal processing, or a structure formed by BMC (Bulk Molding Compound).
With this arrangement, since the plurality of holes are formed on the side of the optical component casing, the parts of the positioning jigs can be inserted through the plurality of holes so that the optical component can be positioned by way of the positioning jigs. Therefore, as compared to the optical component casing having an external position reference face therein and requiring highly accurate manufacturing, the optical component casing can easily be manufactured and the production cost thereof can be reduced without requesting high manufacturing accuracy.
Further, as compared to the above-described optical component casing, the positioning member can be omitted so that the production cost of the optical component casing can further be reduced and the weight of the optical component casing can be reduced, and consequently, the weight of the optical unit can be reduced. Further, when the optical unit is manufactured, the placement process of the positioning member can be simplified, thus quickly manufacturing the optical unit and reducing the production cost of the optical unit.
A projector according to still further aspect of the present invention includes: the above optical component casing; a plurality of optical components housed and arranged in the optical component casing to form an optical image in accordance with image information; and a projection optical device for projecting the optical image formed by the plurality of optical components in an enlarged manner.
According to the above aspect of the present invention, since the projector has the above-described optical component casing, the same functions and advantages as the above-described optical component casing can be obtained. Further, since the manufacturing of the optical component casing is facilitated while the production cost thereof is reduced, the manufacturing of the projector is also facilitated while the production cost thereof is reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing structure of a projector including an optical component casing according to a first embodiment;
FIG. 2 is a plan view schematically showing inside structure of an optical unit according to the aforesaid embodiment;
FIG. 3 is a perspective view showing structure of a container according to the aforesaid embodiment;
FIG. 4 is an illustration to explain a lens holding structure according to the aforesaid embodiment;
FIG. 5 is an illustration to explain a dichroic mirror holding structure according to the aforesaid embodiment;
FIG. 6 is an illustration to explain a reflection mirror holding structure according to the aforesaid embodiment;
FIG. 7 is a cross-sectional view showing structure of a rework member according to the aforesaid embodiment;
FIG. 8 is a cross-sectional view showing structure of a rework member according to the aforesaid embodiment;
FIG. 9 is a cross-sectional view showing structure of a rework member according to the aforesaid embodiment;
FIG. 10 is a flowchart explaining a manufacturing method of the optical unit according to the aforesaid embodiment;
FIG. 11 is a flowchart explaining a lens housing arrangement method according to the aforesaid embodiment;
FIG. 12 is a flowchart to explain a dichroic mirror housing arrangement method according to the aforesaid embodiment;
FIG. 13 is a flowchart explaining a reflection mirror housing arrangement method according to the aforesaid embodiment;
FIG. 14 is a perspective view showing structure of a projector including an optical component casing according to a second embodiment;
FIG. 15 is an illustration where a lid of the optical unit is removed according to the aforesaid embodiment;
FIG. 16 is an illustration to explain an optical system according to the aforesaid embodiment;
FIG. 17 is a perspective view showing an upper side of the container according to the aforesaid embodiment;
FIG. 18 is a perspective view showing a lower side of the container according to the aforesaid embodiment;
FIG. 19 is an entire perspective view showing brief structure of a manufacturing apparatus of the optical unit according to the aforesaid embodiment;
FIG. 20 is a perspective view showing brief structure of an optical component positioning jig according to the aforesaid embodiment;
FIG. 21 is a perspective view showing structure of a first positioning jig according to the aforesaid embodiment;
FIG. 22 is an illustration showing holding structure of a first holder for the optical component according to the aforesaid embodiment;
FIG. 23 is a perspective view showing structure of a second positioning jig according to the aforesaid embodiment;
FIG. 24 is an illustration showing holding structure of a second holder for the optical component according to the aforesaid embodiment;
FIG. 25 is a perspective view showing structure of a third positioning jig according to the aforesaid embodiment;
FIG. 26 is a schematic illustration showing structure of an optical image detecting device according to the aforesaid embodiment;
FIG. 27 is an illustration showing a modification of the optical image detecting device according to the aforesaid embodiment;
FIG. 28 is a block diagram schematically showing control structure of a control device according to the aforesaid embodiment;
FIG. 29 is a flowchart explaining a manufacturing method of the optical unit according to the aforesaid embodiment;
FIG. 30 is a flowchart explaining a manufacturing method of the optical unit according to the aforesaid embodiment;
FIG. 31 is an illustration to explain a method for placing the optical component on the optical component positioning jig according to the aforesaid embodiment;
FIG. 32 is a flowchart explaining a manufacturing method of the optical unit according to the aforesaid embodiment;
FIG. 33 is an illustration showing the state that the container and the optical component are placed on the manufacturing apparatus according to the aforesaid embodiment;
FIG. 34 is an illustration showing an example of an image captured by the control device, which is an optical image picked by the optical image detecting device, according to the aforesaid embodiment;
FIG. 35 is a flowchart explaining a manufacturing method of the optical unit according to the aforesaid embodiment;
FIG. 36 is an illustration showing an example of an image captured by the control device, which is an optical image picked by the optical image detecting device, according to the aforesaid embodiment;
FIG. 37 is an illustration showing an example of a method for, acquiring a luminance curve by a luminance curve acquiring unit according to the aforesaid embodiment;
FIG. 38 is an illustration showing a part of the luminance curve in an enlarged manner according to the aforesaid embodiment;
FIG. 39 is an illustration showing an example of an image captured by the control device, which is an optical image picked by the optical image detecting device, according to the aforesaid embodiment;
FIG. 40 is an illustration to explain a manufacturing method of the optical unit according to the aforesaid embodiment;
FIG. 41 is a flowchart explaining a manufacturing method of the optical unit according to the aforesaid embodiment;
FIG. 42 is an illustration showing an example of an image captured by the control device, which is an optical image picked by the optical image detecting device, according to the aforesaid embodiment;
FIG. 43 is a flowchart explaining a manufacturing method of the optical unit according to the aforesaid embodiment;
FIG. 44 is an illustration showing an example of an image captured by the control device, which is an optical image picked by the optical image detecting device, according to the aforesaid embodiment;
FIG. 45 is a flowchart explaining a manufacturing method of the optical unit according to the aforesaid embodiment;
FIG. 46 is an illustration showing an example of an image captured by the control device, which is an optical image picked by the optical image detecting device, according to the aforesaid embodiment;
FIG. 47 is an illustration to explain a manufacturing method of the optical unit according to the aforesaid embodiment;
FIG. 48 is a perspective view showing an upper side of a container of an optical component casing according to a third embodiment;
FIG. 49 is an illustration in which a part of FIG. 48 is enlarged;
FIG. 50 is an illustration showing the state that the optical component is supported by the container of FIG. 48;
FIG. 51 is a flowchart explaining a method for fixing the position of the optical component not requiring adjustment on the container according to the aforesaid embodiment;
FIG. 52 is a flowchart explaining a method for fixing the position of the optical component requiring adjustment on the container according to the aforesaid embodiment;
FIG. 53 is an illustration showing a modification of the container according to the aforesaid embodiment;
FIG. 54 is an illustration showing a modification of the container according to the aforesaid embodiment;
FIG. 55 is a perspective view showing an upper side of a container of an optical component casing according to a fourth embodiment;
FIG. 56 is a perspective view showing the upper side of the container according to the aforesaid embodiment;
FIG. 57 is an illustration showing a lens holding structure according to the aforesaid embodiment;
FIG. 58 is an illustration showing a reflection mirror holding structure according to the aforesaid embodiment;
FIG. 59 is a flowchart explaining a method for manufacturing an optical unit according to a fifth embodiment; and
FIG. 60 is an illustration showing the state of step S 20 ′ of FIG. 59.
BEST MODE FOR CARRYING OUT THE INVENTION
(1) FIRST EMBODIMENT
A first embodiment of the present invention will be described below with reference to the attached drawings.
(1-1) Structure of Projector
FIG. 1 is a perspective view showing structure of a projector 1 including an optical component casing according to the present embodiment.
The projector 1 modulates a light beam irradiated by a light source in accordance with image information and projects the light beam on a projection surface such as a screen in an enlarged manner. The projector 1 , as shown in FIG. 1, has a planarly-viewed L-shaped optical unit 2 and a projection lens 3 as a projection optical device connected to an end of the optical unit 2 .
Incidentally, though not particularly shown, the projector 1 includes a power source unit for providing electric power supplied from the outside to the components of the projector 1 , a control board for controllably driving a below-described liquid crystal panel of the optical unit 2 and a cooling unit having a cooling fan for blowing cooling air to the components of the projector 1 in addition to the optical unit 2 and the projection lens 3 .
As shown in FIG. 1 with a dotted line, the respective components of the projector 1 such as the optical unit 2 , a part of the projection lens 3 , the power source unit, the control board and the cooling unit etc. are housed in an exterior case 20 . The projection lens 3 is arranged in the state that an image can be projected outside through an opening of the exterior case 20 .
Under the control of the control board (not shown), the optical unit 2 forms an optical image in accordance with image information provided from the outside. Though described below in detail, as shown in FIG. 1, the optical unit 2 includes an optical component casing 25 that has a casing body constituted of a container 25 A formed in a container-shape and a lid 25 B for closing an opening of the container 25 , a plurality of optical components arranged and housed in the optical component casing 25 and a head 26 connected to the optical component casing 25 to support the projection lens 3 and an electric optical device 24 .
The projection lens 3 enlarges and projects the optical image modulated by the optical unit 2 in accordance with image information. The projection lens 3 is a lens set including a plurality of lenses housed in a cylindrical lens barrel, which has a lever (not shown) capable of changing the relative position of the plurality of lenses so that the focus and magnification of the projected image can be adjusted.
(1-2) Structure of Optical System
FIG. 2 is a plan view schematically showing the inside structure of the optical unit 2 . Specifically, FIG. 2 is an illustration of the optical unit 2 with the lid 25 B removed.
As shown in FIG. 2, the optical components of the projector 1 according to the present embodiment include an integrator illuminating optical system 21 , a color-separating optical system 22 , a relay optical system 23 and the electric optical device 24 integrating an optical modulator and a color-combining optical device.
The integrator illuminating optical system 21 is an optical system for equalizing the illuminance of the light beam irradiated by the light source on a plane orthogonal to the illumination optical axis. As shown in FIG. 2, the integrator illuminating optical system 21 has a light source device 211 , a first lens array 212 , a second lens array 213 , a polarization converter 214 and a superposing lens 215 .
The light source device 211 has a light source lamp 216 (a radial light source), a reflector 217 and a protection glass 218 covering the light-irradiation side of the reflector 217 . The radial light beam irradiated by the light source lamp 216 is reflected by the reflector 217 to be an approximately parallel light beam and is irradiated toward the outside. In the present embodiment, a high-pressure mercury lamp is used as the light source lamp 216 and a parabolic mirror is used as the reflector 217 . Incidentally, the light source lamp 216 may not be a high-pressure mercury lamp but may be a metal halide lamp or a halogen lamp. Further, though a parabolic mirror is used as the reflector 217 , a parallelizing concave lens disposed on an irradiation-side of a reflector of an ellipsoidal mirror may alternatively be used.
The first lens array 212 has small lenses arranged in a matrix, the lenses having substantially rectangular profile seen in the illumination optical axis direction. The respective lenses separates the light beam irradiated by the light source lamp 216 into sub-beams and emits the sub-beams in the illumination optical axis direction.
The second lens array 213 is arranged approximately in the same manner as the first lens array 212 , which includes small lenses arranged in a matrix. The second lens array 213 together with the superposing lens 215 superposes the image of the respective small lenses of the first lens array 212 onto the image formation areas of the below-described liquid crystal panels 241 R, 241 G and 241 B of the electric optical device 24 .
The polarization converter 214 converts the light from the second lens array 213 into substantially uniform polarized light, thereby enhancing the light utilization efficiency of the electric optical device 24 .
Specifically, the respective sub-beams converted into substantially uniform polarized light by the polarization converter 214 are substantially superposed on the image formation areas of the below-described liquid crystal panels 241 R, 241 G and 241 B of the electric optical device 24 by the superposing lens 215 . Since only one-type of polarized light can be used in a projector using the liquid crystal panels 241 R, 241 G and 241 B that modulate a polarized light, approximately half of the light beam from the light source lamp 216 emitting random polarized light cannot be used. Accordingly, with the use of the polarization converter 214 , the light beam irradiated by the light source lamp 216 is converted into substantially uniform polarized light to enhance the light utilization efficiency of the electric optical device 24 . Incidentally, such polarization converter 214 is disclosed in, for instance, JP H08-304739A.
The color-separating optical system 22 has two dichroic mirrors 221 and 222 , and a reflection mirror 223 . The plurality of sub-beams irradiated by the integrator illuminating optical system 21 are separated into three color lights of red (R), green (G) and blue (B) by the two dichroic mirrors 221 .
The relay optical system 23 has an incident-side lens 231 , a relay lens 233 , and reflection mirrors 232 and 234 . The relay optical system 23 guides the color light (blue light) separated by the color-separating optical system 22 toward the below-described liquid crystal panel 241 B of the electric optical device 24 .
At this time, the dichroic mirror 221 of the color-separating optical system 22 transmits the green light component and blue light component of the light beam irradiated by the integrator illuminating optical system 21 and reflects the red light component. The red light reflected by the dichroic mirror 221 is reflected by the reflection mirror 223 , which reaches to the liquid crystal panel 241 R for red color through the field lens 224 . The field lens 224 converts the respective sub-beams irradiated by the second lens array 213 into a light beam parallel to the central axis (main beam) thereof. The field lenses 224 provided on the light-incident side of the other liquid crystal panels 241 G and 241 B function in the same manner.
In the blue and green lights passed through the dichroic mirror 221 , the green light is reflected by the dichroic mirror 222 , which reaches to the liquid crystal panel 241 G for green light through the field lens 224 . On the other hand, the blue light passes through the dichroic mirror 222 , which passes through the relay optical system 23 to reach the liquid crystal panel 241 B for blue light through the field lens 224 .
Incidentally, the relay optical system 23 is used for the blue light in order to avoid deterioration in the light utilization efficiency on account of light dispersion and the like caused by the longer length of the optical path of the blue light than the optical path of the other color light. In other words, the relay optical system 23 is used for directly transmitting the sub-beams incident on the incident-side lens 231 to the field lens 224 . Incidentally, though the blue light of the three color lights passes through the relay optical system 23 , the red light, for instance, may alternatively pass through the relay optical system 23 .
The electric optical device 24 modulates the incident light beam in accordance with image information to form a color image. The electric optical device 24 has three incident-side polarization plates 242 on which the respective color lights separated by the color-separating optical system 22 are incident, the liquid crystal panels 241 R, 241 G and 241 B (optical modulators) and irradiate-side polarization plates 243 disposed on the downstream of the respective incident-side polarization plates 242 , and a cross dichroic prism 244 (color-combining optical device).
The liquid crystal panels 241 R, 241 G and 241 B use, for instance, a polycrystalline silicon TFT as a switching element, which has a pair of opposing transparent substrates with liquid crystal sealed therebetween. The liquid crystal panels 241 R, 241 G and 241 B irradiate the light beam incident thereon through the incident-side polarization plates 242 after modulating in accordance with image information. Incidentally, the liquid crystal panels 241 R, 241 G and 241 B are held and accommodated in a holder frame (not shown).
The incident-side polarization plate 242 transmits a polarized light in a predetermined direction out of the respective color lights separated by the color-separating optical system 22 and absorbs the other light beam, which have a substrate made of sapphire glass and the like with a polarization film attached thereon.
The irradiation-side polarization plate 243 is also arranged substantially in the same manner as the incident-side polarization plate 242 , which transmits the polarized light in a predetermined direction out of the light beam irradiated by the liquid crystal panels 241 R, 241 G and 241 B, where the polarization axis of the transmitted polarized light is set orthogonal to the polarization axis of the polarized light passed through the incident-side polarization plate 242 .
The cross dichroic prism 244 combines the optical image irradiated by the irradiation-side polarization plate 243 and modulated for each color light to form a color image. In the cross dichroic prism 244 , a dielectric multi-layer film for reflecting the red light and a dielectric multi-layer film for reflecting the blue light are formed along the boundaries of four right-angle prisms approximately in X-shape, the dielectric multi-layer films combining the three color lights.
Incidentally, the cross dichroic prism 244 is fixed on a mount (not shown). Further, the liquid crystal panels 241 R, 241 G and 241 B, and the three irradiation-side polarization plates 243 are respectively fixed on the three light incident sides of the cross dichroic prism 244 to be unitized. Hereinafter, the unit, in which the cross dichroic prism 244 , the mount, the liquid crystal panels 241 R, 241 G and 241 B and the three irradiation-side polarization plates 243 are integrated, is called as a “prism unit” for convenience.
Note that, the electric optical device 24 may be equipped with a visual-angle corrector plate arranged between the incident-side polarization plate 242 and the irradiation-side polarization plate 243 to correct the visual field angle of the optical image formed by the liquid crystal panels 241 R, 241 G and 241 B in addition to the liquid crystal panels 241 R, 241 G and 241 B, the incident-side polarization plate 242 , the irradiation-side polarization plate 243 and the cross dichroic prism 244 . The visual field angle of the projection image is enlarged and the contrast of the projected image is enhanced since the visual-angle corrector plate is arranged.
(1-3) Structure of Optical Component Casing
As shown in FIG. 1 or 2 , the optical component casing 25 includes the container 25 A in which the various optical components of the above-described optical systems 21 , 22 and 23 and the electric optical device 24 are housed, the lid 25 B (FIG. 1) for closing the upper opening of the container 25 A, a positioning member 253 for positioning the optical components of the optical systems 21 , 22 and 23 excluding the light source device 211 at predetermined positions in the container 25 A, and rework members 254 X, 254 Y and 254 Z (not shown here) appropriately mounted on the outer side of the optical component casing 25 to be able to rework the various optical components housed and arranged in the container 25 A.
FIG. 3 is a perspective view showing structure of the container 25 A.
As shown in FIGS. 1 to 3 , the container 25 A made of an aluminum plate by sheet metal processing includes a light source housing 250 for housing the light source device 211 , and a component housing 251 for housing the optical components of the optical systems 21 , 22 and 23 (FIG. 2) excluding the light source device 211 . The light source housing 250 and the component housing 251 are formed in a container-shape by drawing with the lower side of the light source housing 250 being opened and the upper side of the component housing 251 being opened. An opening 251 H (FIG. 3) is formed on a connection of the light source housing 250 with the component housing 251 by cutting etc. so that the light beam irradiated by the light source device 211 passes through the opening 251 H.
Incidentally, the light source housing 250 and the component housing 251 may be formed with a single plate by drawing. Further, the light source housing 250 and the component housing 251 may be respectively formed with two plates by drawing so that the two housings are mechanically joined by a screw etc. or by welding.
The light source housing 250 houses and arranges the light source device 211 (FIG. 2) from the opening (not shown) on the lower side. Though not shown, a slit-shaped opening is formed on a lateral side of the light source housing 250 by cutting etc. so that the air heated by the heat generated at the light source device 211 does not stay inside the light source housing 250 .
As shown in FIG. 3, an end of the component housing 251 is connected to the light source housing 250 , and the other end thereof is formed in an approximately planarly-viewed C-shaped container to which the head 26 is connected.
In the component housing 251 , a plurality of holes 251 A are formed on the lateral side by cutting and folding parts of the lateral side to the inside of the component housing 251 corresponding to the positions of the optical components 212 to 215 , 231 and 233 (FIG. 2). Further, a plurality of circular holes 251 C are formed on the lateral side to penetrate toward the inside corresponding to the positions of the optical components 223 , 232 and 234 (FIG. 2). Cutouts 251 J are formed on an inner lateral side of the approximately planarly-viewed C-shape by cutting etc. so that the three color lights irradiated by the light source device 211 (FIG. 2) and separated by the color-separating optical system 22 (FIG. 2) can pass through the cutouts 251 J toward the electric optical device 24 (FIG. 2).
Though not shown, a plurality of burring holes with screw grooves are formed on a bottom side and an upper end of the component housing 251 .
As shown in FIG. 1, the lid 25 B is an aluminum plate, which is formed by cutting etc. to close an upper opening of the component housing 251 of the container 25 A. Though not shown, a plurality of holes are formed on the lid 25 B so that the lid 25 B is fixed to the container 25 A by screws etc. through the holes and burring holes (not shown) formed on the container 25 A.
The inner sides of the light source housing 250 and the component housing 251 of the above-described container 25 A and the lower side of the lid 25 B are coated with anodized black-aluminum.
As shown in FIG. 1 or 2 , the positioning member 253 include first positioning members 253 A as orthogonal arrangement positioning members for respectively positioning the first lens array 212 , the second lens array 213 , the polarization converter 214 , the superposing lens 215 , the incident-side lens 231 and the relay lens 233 , second positioning members 253 B (FIG. 2) as inclined arrangement positioning members for respectively positioning the dichroic mirrors 221 and 222 , and third positioning members 253 C as parallel arrangement positioning members for respectively positioning the reflection mirrors 223 , 232 and 234 . The positioning member 253 will be described at the same time when holding structure of the optical component is described. The rework members 254 X, 254 Y and 254 Z will be described in detail after the holding structure of the optical component is described.
(1-4) Structure of Head
The head 26 is made of magnesium alloy, which is formed in an approximately L shape-sided portion. As shown in FIG. 2, the head 26 integrates the projection lens 3 and a plurality of optical elements. The head 26 includes a lens supporter 261 formed on an outer vertical side of the approximately L shape-sided portion, a mount face 262 formed on an upper horizontal side of the approximately L shape-sided portion, and field lens holders 263 projected on the mount face 262 .
Note that, the head 26 may be made of aluminum, magnesium and titanium or alloy containing the above metal as main components without limiting to the magnesium alloy.
As shown in FIG. 1 or 2 , the lens supporter 261 is formed in a rectangular shape, on which fixing female screw holes (not shown) are formed on four corners of the rectangular shape by penetrating through it in order to fix the projection lens 3 . The lens supporter 261 supports and fixes the projection lens 3 by screwing screws etc. into the fixing female screw holes via holes (not shown) of the projection lens 3 .
As shown in FIG. 2, the mount face 262 is formed in an approximately planarly-viewed rectangular shape. The prism unit is mounted and fixed on the mount face 262 at the approximate center in a horizontal direction near the lens supporter 261 . The prism unit is fixed on the mount face 262 through the mount. Three cutouts 262 A for circulating the cooling air blown from the cooling unit (not shown) are formed on the mount face 262 at the side of the liquid crystal panels 241 R, 241 G and 241 B.
The field lens holders 263 extends upward from corners of the cutouts 262 A formed on the mount face 262 to support and fix the field lens 224 .
For instance, a plurality of holes (not shown) are formed on the mount face 262 of the above-described head 26 so that the head 26 is fixed on the container 25 A by screws etc. through the holes and the burring holes (not shown) formed on the container 25 A.
Though not particularly shown, fixing structure of the incident-side polarization plate 242 may employ a configuration that a polarization film is attached to the light-irradiation side of the field lens 224 or structure that holds and fixes the incident-side polarization plate 242 on a member projected upward from the mount face 262 in the same manner as the field lens holder 263 .
(1-5) Holding Structure of Optical Component
Next, holding structure of the optical components of the optical systems 21 , 22 and 23 (FIG. 2) excluding the light source device 211 on the optical component casing 25 will be described.
The holding structures of the optical components can be classified into three holding structures by grouping similar structures. In other words, the holding structures can be classified into a lens holding structure for holding the first lens array 212 , the second lens array 213 , the polarization converter 214 , the superposing lens 215 , the incident-side lens 231 and the relay lens 233 , a dichroic mirror holding structure for holding the dichroic mirrors 221 and 222 , and a reflection mirror holding structure for holding the reflection mirrors 223 , 232 and 234 . In the following, the above three holding structures will be sequentially described.
(1-5-1) Lens Holding Structure
FIG. 4 is an illustration to explain the lens holding structure. As mentioned above, since the holding structures of the optical components 212 to 215 , 231 and 233 have similar structures, the holding structure of the superposing lens 215 will mainly be described here.
As shown in FIG. 4, the planarly-viewed circular superposing lens 215 is a convex lens, of which a light-incident side and a light-irradiation side are spherically bulged. Two first positioning members 253 A out of the above-described plurality of first positioning members 253 A are used as members for holding the superposing lens 215 .
The first positioning member 253 A is made of synthetic resin (acrylic material) transmitting ultraviolet ray and formed in a quadratic prism member which is inserted through the hole 251 A formed on the lateral side of the container 25 A. A groove 253 A 1 having an approximately V-shaped cross-section is formed on an end of the quadratic prism of the first positioning member 253 A. The groove 253 A 1 is formed to have the approximately same shape as a cross-section of an outer periphery of the superposing lens 215 . Further, a rework screw hole 253 A 2 is formed on the other end of the first positioning member 253 A with the rework screw hole 253 A 2 extending toward the end.
In the holes 251 A of the container 25 A, the cut and folded part of the lateral side serves as a support portion 251 K of the first positioning member 253 A.
The first positioning members 253 sandwich the superposing lens 215 from left and right directions by the grooves 253 A 1 abutting on the outer periphery of the superposing lens 215 through the holes 251 A formed on the lateral side of the container 25 A. At this time, an ultraviolet curing adhesive is filled between the first positioning member 253 and the support portion 251 K, and between the groove 253 A 1 of the first positioning member 253 and the outer periphery of the superposing lens 215 , so that the superposing lens 215 is held and fixed on the optical component casing 25 by curing the adhesive.
Incidentally, other holding structures of the optical components 212 to 214 , 231 and 233 are similar to the above-described holding structure of the superposing lens 215 .
(1-5-2) Dichroic Mirror Holding Structure
FIG. 5 is an illustration to explain the dichroic mirror holding structure. As mentioned above, since the holding structures of the dichroic mirrors 221 and 222 have similar structures, the holding structure of the dichroic mirror 222 will mainly be described here.
As shown in FIG. 5, the dichroic mirror 222 is an approximately planarly-viewed rectangular shape, which is held by the second positioning member 253 B.
As shown in FIG. 5, the second positioning member 253 B includes a plate-shaped mount 253 B 1 fixed on a bottom side of the component housing 251 of the container 25 A, a pair of plate members 253 B 2 fixed on an upper side of the mount 253 B 1 and having an L-shaped cross-section, and spacers 253 B 3 interposed between the pair of plate members 253 B 2 and left and right ends of the dichroic mirror 222 .
The pair of plate members 253 B 2 opposes to the lateral side of the component housing 251 of the container 25 A in approximately parallel, with an end of the L-shaped cross-sectional shape being fixed on the upper side of the mount 253 B 1 and the other end thereof extending upward the mount 253 B 1 . The dichroic mirror 222 is arranged between the pair of plate members 253 B 2 in an inclined manner so that left and right ends of the dichroic mirror 222 opposes to the other ends of the plate members 253 B 2 .
In the pair of plate members 253 B 2 , a part of the other end is cut and folded toward the opposing plate member 253 B 2 in a triangular shape, which serves as a support portion 253 B 4 for supporting the spacer 253 B 3 .
An opening 253 B 5 is formed on the other end near the field lens 224 (FIG. 2) out of the other ends of the pair of plate members 253 B 2 so that the green light reflected by the dichroic mirror 222 is passed through the opening 253 B 5 .
The spacer 253 B 3 is a triangular prism member made of synthetic resin (acrylic material) transmitting ultraviolet ray in the same manner as the first positioning member 253 A. A rework screw hole 253 B 6 (not shown) is formed on an upper end of the spacer 253 B 3 with the rework screw hole 253 B 6 extending toward a lower end thereof. The spacer 253 B 3 is supported by the support portion 253 B 4 and interposed between the left or right end of the dichroic mirror 222 and the plate member 253 B 2 . At this time, an inclined direction of a slanted face of the triangular prism of the spacer 253 B 3 is configured to be the approximately same direction as an inclined direction of the dichroic mirror 222 . The ultraviolet curing adhesive is filled between the spacer 253 B 3 and the support portion 253 B 4 , and between the slanted face of the spacer 253 B 3 and an outer periphery of the dichroic mirror 222 , so that the dichroic mirror 222 is held and fixed on the optical component casing 25 by curing the adhesive.
Incidentally, the other holding structure of the dichroic mirror 221 is similar to the above-described holding structure of the dichroic mirror 222 .
(1-5-3) Reflection Mirror Holding Structure
FIG. 6 is an illustration to explain the reflection mirror holding structure. As mentioned above, since the holding structures of the reflection mirrors 223 , 232 and 234 have similar structures, the holding structure of the reflection mirror 232 will mainly be described here.
As shown in FIG. 6, the reflection mirror 232 is an approximately planarly-viewed rectangular shape, of which an end has a reflection face depositing highly reflective aluminum etc. The above-described third positioning member 253 C is used as a member for holding the reflection mirror 232 .
The third positioning member 253 C made of synthetic resin (acrylic member) transmitting ultraviolet ray includes a plate body 253 C 1 and cylindrical four pins 253 C 2 projected from four corners of an end of the plate body 253 C 1 with the pins 253 C 2 being orthogonal to the end.
Though not shown, a rework screw hole 253 C 3 extending inside the pin 253 C 2 is formed on a back side of the plate body 253 C 1 .
The pin 253 C 2 is inserted to the third positioning member 253 C through a hole 251 C formed on the lateral side of the container 25 A so that an tip end of the pin 253 C 2 abuts on a back side of a reflection face of the reflection mirror 232 . At this time, an ultraviolet curing adhesive is filled between the pin 253 C 2 and the back side of the reflection face of the reflection mirror 232 , and between a periphery of the pin 253 C 2 and the hole 251 C, so that the reflection mirror 232 is held and fixed on the optical component casing 25 by curing the adhesive.
Incidentally, other holding structures of the reflection mirrors 223 and 234 are similar to the above-described holding structure of the reflection mirror 232 .
Though the above-described first positioning member 253 A, the spacer 253 B 3 and the third positioning member 253 C are made of acrylic material, they may be made of other synthetic resins transmitting ultraviolet ray or, alternatively, may be made of optical glass, crystal, sapphire glass, quartz or the like.
Further, though the ultraviolet curing adhesive is used for the lens holding structure, the dichroic mirror holding structure and the reflection mirror holding structure may employ a wide variety of adhesives, preferably, the main component is acrylate and its viscosity is 17000 P.
(1-6) Structure of Rework Member
FIGS. 7 to 9 are perspective views respectively showing structures of the rework members 254 X, 254 Y and 254 Z.
When the various optical components 212 to 215 held by the above-described holding structures shown in FIG. 4 are replaced and so on, the rework member 254 X releases the adhered and fixed state on the optical component casing 25 . As shown in FIG. 7, the rework member 254 X is formed in a shape having an approximately c-shaped cross-section by bending an aluminum plate, and includes a support member 254 A of which a hole 254 A 1 is formed on an end opposite to an opening side, and a rework screw 254 B disposed on the hole 254 A 1 of the support member 254 A to screw into the rework screw hole 253 A 2 of the first positioning member 253 A.
When the various optical components 221 and 222 held by the above-described holding structures shown in FIG. 5 are replaced and so on, the rework member 254 Y releases the adhered and fixed state on the optical component casing 25 . As shown in FIG. 8, the rework member 254 Y is formed in a shape having an approximately c-shaped cross-section by bending an aluminum plate, and includes a support member 254 A of which a hole 254 A 1 is formed on an end opposite to an opening side, and a rework screw 254 B disposed on the hole 254 A 1 of the support member 254 A to screw into the rework screw hole 253 B 6 of the spacer 253 B 3 .
When the various optical components 223 , 232 and 234 held by the above-described holding structures shown in FIG. 6 are replaced and so on, the rework member 254 Z releases the adhered and fixed state on the optical component casing 25 . As shown in FIG. 9, the rework member 254 Z is formed in a shape having an approximately c-shaped cross-section by bending an aluminum plate, and includes a support member 254 A of which a hole 254 A 1 is formed on an end opposite to an opening side, and a rework screw 254 B disposed on the hole 254 A 1 of the support member 254 A to screw into the rework screw hole 253 C 3 of the plate body 253 C 1 .
(1-7) Manufacturing Method of Optical Unit
FIG. 10 is a flowchart explaining the manufacturing method of the optical unit 2 according to the present embodiment. Referring to FIG. 10, a manufacturing method of the optical unit 2 will be described below.
Firstly, the light source device 211 is housed and arranged in the light source housing 250 of the container 25 A. Then, the projection lens 3 is placed on the lens supporter 261 of the head 26 , the electric optical device 24 is mounted and fixed on the mount face 262 , and the field lens 224 is held and fixed on the field lens holder 263 . The head 26 is connected to the component housing 251 of the container 25 A by a screw (not shown) etc.
Secondly, the optical components 212 to 215 , 221 to 223 and 231 to 234 are housed and arranged in the component housing 251 of the container 25 A (step S 1 ). As mentioned above, since the holding structures of the optical components can be classified into the three holding structures of the lens holding structure, the dichroic mirror holding structure and the reflection mirror holding structure by grouping similar structures, hereinafter, a lens housing arrangement method, a dichroic mirror housing arrangement method and a reflection mirror housing arrangement method are sequentially described.
(1-7-1) Lens Housing Arrangement Method (Step S 11 )
FIG. 11 is a flowchart to explain the lens housing arrangement method.
As described above, since the housing arrangement methods of the optical components 212 to 215 , 231 and 233 are similar, the housing arrangement method of the superposing lens 215 will mainly be described here with reference to FIGS. 4 and 11. Note that, similar housing arrangement methods are applied to other optical components 212 to 214 , 231 and 233 .
Firstly, an ultraviolet curing adhesive is applied on the grooves 253 A 1 and the peripheries of the two first positioning members 253 A. (step S 111 ).
The first positioning members 253 with the adhesive applied are inserted into the holes 251 A formed on the lateral side of the container 25 A to place the superposing lens 215 so as to be sandwiched between both left and right sides thereof (step S 112 ). At this time, the first positioning members 253 are held by the support portions 251 K.
The superposing lens 215 is housed in the component housing 251 from the upper side of the component housing 251 to be arranged between the two first positioning members 253 placed in the step S 112 (step S 113 ), and the outer periphery of the superposing lens 215 abuts on the grooves 253 A 1 of the first positioning members 253 (step S 114 ).
(1-7-2) Dichroic Mirror Housing Arrangement Method (Step S 12 )
FIG. 12 is a flowchart explaining the dichroic mirror housing arrangement method.
As described above, since the housing arrangement methods of the dichroic mirrors 221 and 222 are similar, the housing arrangement method of the dichroic mirror 222 will mainly be described here with reference to FIGS. 5 and 12. Note that, a similar housing arrangement method is applied to the dichroic mirror 221 .
Firstly, the ultraviolet curing adhesive is applied on the peripheries of the two spacers 253 B 3 (step S 121 ).
The spacers 253 B 3 with the adhesive applied are respectively mounted on the support portions 253 B 4 of the pair of plate members 253 B 2 (step S 122 ).
The dichroic mirror 222 is arranged between the pair of plate members 253 B 2 in an inclined manner relative to the end of the plate members 253 B 2 (step S 123 ) to abut on the spacers 253 B 3 mounted on the support portions 253 B 4 in the step S 122 (step S 124 ).
Then, in the steps S 121 to S 124 , the second positioning member 253 B in which the dichroic mirror 222 is held is housed in the component housing 251 of the container 25 A to fix the mount 253 B 1 on the bottom side of the component housing 251 (step S 125 ).
(1-7-3) Reflection Mirror Housing Arrangement Method (Step S 13 )
FIG. 13 is a flowchart explaining the reflection mirror housing arrangement method.
As described above, since the housing arrangement methods of the reflection mirrors 223 , 232 and 234 are similar, the housing arrangement method of the reflection mirror 232 will mainly be described here with reference to FIGS. 6 and 13. Note that, similar housing arrangement methods are applied to other reflection mirrors 223 and 234 .
Firstly, the ultraviolet curing adhesive is applied on tip ends and the peripheries of the four pins 253 C 2 of the third positioning member 253 C (step S 131 ).
The pins 253 C 2 of the third positioning member 253 C with the adhesive applied are inserted into the holes 251 C formed on the lateral side of the container 25 A (step S 132 ).
Then, the reflection mirror 232 is housed in the component housing 251 from the upper side of the component housing 251 to oppose the pins 253 C 2 of the third positioning member 253 C placed in the step S 132 (step S 133 ), and the back side of the reflection face of the reflection mirror 232 abuts on the tip ends of the pins 253 C 2 of the third positioning member 253 C (step S 134 ).
(1-7-4) Positioning Method of Optical Component
After the above-described steps SI, while the ultraviolet curing adhesive is uncured, the optical components 212 to 215 , 221 to 223 and 231 to 234 are adjusted to be positioned at the predetermined positions (step S 2 ).
More specifically, the light source device 211 is operated to irradiate the light beam of white light, an image light, which is the irradiated light beam after passing through the various optical components, is projected on a screen (not shown) through the projection lens 3 , the positions of the various optical components are adjusted while the projected image is checked, and the optical components are positioned at the predetermined positions.
If the positions of the optical axis among the various optical components 212 to 215 , 221 to 223 and 231 to 234 are misaligned, shade is displayed on the projected image on account of a deviation at the positions of the optical components. In such situation, the various optical components are positioned at the predetermined positions on the illumination optical axis of the light beam irradiated by the light source device 211 to eliminate the shade in the projected image.
For example, at the positioning of the optical components 212 to 215 , 231 and 233 , an optical axis adjustment fixture (not shown) is engaged with the optical components 212 to 215 , 231 and 233 from the outside of the optical component casing 25 . While the projected image is checked, the optical axis adjustment fixture is operated so that the positions of the optical components 212 to 215 , 231 and 233 are adjusted according to five axes respectively in a horizontal direction, a vertical direction, a cross direction, an out-plane rotary direction around the horizontal direction as its axis, and an out-plane rotary direction around the vertical direction as its axis of the optical components. At this time, on account of the surface tension of the ultraviolet curing adhesive, the first positioning members 253 A follow when the optical components 212 to 215 , 231 and 233 shift, so that the first positioning members 253 A position the optical components 212 to 215 , 231 and 233 at the predetermined positions.
For another example, at the positioning of the dichroic mirrors 221 and 222 , an optical axis adjustment fixture (not shown) is also engaged with the dichroic mirrors 221 and 222 . While the projected image is checked, the optical axis adjustment fixture is operated so that the positions of the dichroic mirrors 221 and 222 are adjusted according to five axes respectively in a horizontal direction, a vertical direction, a cross direction, an out-plane rotary direction around the horizontal direction as its axis, and an out-plane rotary direction around the vertical direction as its axis of the dichroic mirrors. At this time, on account of the surface tension of the ultraviolet curing adhesive, the spacers 253 B 3 follow when the dichroic mirrors 221 and 222 shift, so that the spacers 253 B 3 position the dichroic mirrors 221 and 222 at the predetermined positions.
For further example, at the positioning of the reflection mirrors 223 , 232 and 234 , an optical axis adjustment fixture (not shown) is also engaged with the plate bodies 253 C 1 of the third positioning members 253 C. While the projected image is checked, the optical axis adjustment fixture is operated to shift the plate bodies 253 C 1 . At this time, on account of the surface tension of the ultraviolet curing adhesive, the reflection mirrors 223 , 232 and 234 follow when the plate bodies 253 C 1 shift, so that the positions of the reflection mirrors 223 , 232 and 234 are adjusted according to five axes respectively in a horizontal direction, a vertical direction, a cross direction, an out-plane rotary direction around the horizontal direction as its axis, and an out-plane rotary direction around the vertical direction as its axis of the reflection mirrors. At this time, on account of the surface tension of the ultraviolet curing adhesive, the third positioning members 253 C hold the reflection mirrors 223 , 232 and 234 at the predetermined positions so that the third positioning members 253 C position the reflection mirrors 223 , 232 and 234 at the predetermined positions.
(1-7-5) Position Fixing Method of Optical Component
In the step S 2 , after positioning the various optical components 212 to 215 , 221 to 223 and 231 to 234 , the positions of the various optical components are fixed on the optical component casing 25 by irradiating ultraviolet ray among the components to cure the ultraviolet curing adhesive (step S 3 ).
Specifically, for example, at the positioning of the optical components 212 to 215 , 231 and 233 , ultraviolet ray is irradiated from the lateral side of the container 25 A toward the first positioning members 253 A. The irradiated ultraviolet ray passes through the first positioning member 253 A to cure the ultraviolet curing adhesive applied between the first positioning member 253 A and the support portion 251 K as well as the ultraviolet curing adhesive applied between the groove 253 A 1 of the first positioning member 253 A and the peripheral ends of the optical components 212 to 215 , 231 and 233 .
For another example, at the positioning of the dichroic mirrors 221 and 222 , ultraviolet ray is irradiated from the upper side of the container 25 A toward the spacers 253 B 3 . The irradiated ultraviolet ray passes through the spacer 253 B 3 to cure the ultraviolet curing adhesive applied between the spacer 253 B 3 and the support portion 253 B 4 . The irradiated ultraviolet ray also cures the ultraviolet curing adhesive applied between the peripheries of the spacers 253 B 3 and the plate members 253 B 2 as well as the ultraviolet curing adhesive applied between the spacers 253 B 3 and the left and right ends of the dichroic mirrors 221 and 222 .
For further example, at the positioning of the reflection mirrors 223 , 232 and 234 , ultraviolet ray is irradiated from the lateral side of the container 25 A toward the third positioning members 253 C. The irradiated ultraviolet ray passes through the plate body 253 C 1 and the pins 253 C 2 to cure the ultraviolet curing adhesive applied between the peripheries of the pins 253 C 2 and the holes 251 C as well as the ultraviolet curing adhesive applied between the tip ends of the pins 253 C 2 and the back sides of the reflection faces of the reflection mirrors 223 , 232 and 234 .
After the operation of the above steps S 1 to S 3 , the lid 25 B is connected to the container 25 A by a screw etc. (step S 4 ) to manufacture the optical unit 2 .
Incidentally, a hole for engaging the optical axis adjustment fixture (not shown) with the optical components housed inside and a hole for irradiating ultraviolet ray toward the spacers 253 B 3 may be formed on the lid 25 B so that the lid 25 B is connected to the container 25 A after the step S 1 , and the steps S 2 and S 3 are performed in the above state.
(1-7-6) Rework Method of Optical Component
As shown in FIG. 10, in the optical unit 2 manufactured according to the operation of the above-described steps S 1 to S 4 , when the optical component requires to be replaced etc. and the optical component is removed from the optical component casing 25 (step S 5 ), a rework operation (step S 6 ) is performed. In the rework operation (step S 6 ), since the above-described rework members 254 X, 254 Y and 254 Z are used, refer to FIGS. 7 to 9 appropriately when the rework operation (step S 6 ) is described.
When the optical components 212 to 215 , 231 and 233 are removed, the following will be performed. As mentioned above, since the holding structures of the optical components 212 to 215 , 231 and 233 have similar structures, the rework method of the superposing lens 215 will mainly be described here.
Firstly, as shown in FIG. 7, the opening side of the support member 254 A of the rework member 254 X abuts on a position corresponding to the hole 251 A on the lateral side of the container 25 A. The rework screw 254 B arranged on the hole 254 A 1 of the support member 254 A is screwed to the rework screw hole 253 A 2 formed on the first positioning member 253 A. The rework screw 254 B is then rotated in a direction screwing into the rework screw hole 253 A 2 to change the screwing state. Accordingly, since the first positioning member 253 A is moved toward the rework member 254 X, the adhered state between the first positioning member 253 A and the support portion 251 K is released, as is the adhered state between the groove 253 A 1 of the first positioning member 253 A and the outer periphery of the superposing lens 215 , so that the superposing lens 215 is removed from the optical component casing 25 .
When the reflection mirrors 223 , 232 and 234 are removed, the following will be performed. As mentioned above, since the holding structures of the reflection mirrors 223 , 232 and 234 have similar structures, the rework method of the reflection mirror 232 will mainly be described here.
Firstly, as shown in FIG. 9, the opening side of the support member 254 A of the rework member 254 Z abuts on the lateral side of the container 25 A so that the third positioning member 253 C is positioned inside the c-shaped support member 254 A. The rework screw 254 B arranged on the hole 254 A 1 of the support member 254 A is screwed to the rework screw hole 253 C 3 formed on the plate body 253 C 1 of the third positioning member 253 C. The rework screw 254 B is then rotated in a direction screwing into the rework screw hole 253 C 3 to change the screwing state. Accordingly, since the third positioning member 253 C is shifted toward the rework member 254 Z, the adhered state between the peripheries of the pins 253 C 2 of the third positioning member 253 C and the holes 251 C of the container 25 A is released, as is the adhered state between the tip ends of the pins 253 C 2 and the back side of the reflection face of the reflection mirror 232 , so that the reflection mirror 232 is removed from the optical component casing 25 .
Further, when the dichroic mirrors 221 and 222 are removed, the following will be performed.
Firstly, the rework member 254 Y is inserted into a hole (not shown) of the lid 25 B to be attached on an upper end of the plate member 253 B 2 of the second positioning member 253 B. The rework screw 254 B arranged on the hole 254 A 1 of the support member 254 A is screwed to the rework screw hole 253 B 6 formed on the spacer 253 B 3 of the second positioning member 253 B. The rework screw 254 B is then rotated in a direction screwing into the rework screw hole 253 B 6 to change the screwing state. Accordingly, since the spacer 253 B 3 is moved toward the lid member 25 B, the adhered state between the spacer 253 B 3 and the support portion 253 B 4 is released, as is the adhered state between the spacer 253 B 3 and the plate member 253 B 2 , and also between the spacer 253 B 3 and the left and right ends of the dichroic mirrors 221 and 222 , so that the dichroic mirrors 221 and 222 are removed from the second positioning member 253 B.
After performing the above-described rework operation S 6 , the step S 1 is taken to sequentially perform housing, positioning and fixing of the replaced optical component.
(1-8) Advantages of First Embodiment
According to the above-described first embodiment, following advantages can be obtained.
(1-8-1) The optical component casing 25 includes the container 25 A, the lid 25 B and the positioning member 253 . The container 25 A and the lid 25 B are made of an aluminum plate by sheet metal processing. The positioning member 253 positions the various optical components 212 to 215 , 221 to 223 and 231 to 234 housed in the container 25 A. Accordingly, as compared to the conventional optical component casing having an external position reference face therein and requiring highly accurate manufacturing, the optical component casing 25 can easily be manufactured and the production cost can be reduced.
(1-8-2) The container 25 A and the lid 25 B are made of aluminum. Accordingly, the optical component casing 25 is well heat-conductive so as to radiate the heat generated by the optical systems 21 , 22 and 23 and the electric optical device 24 due to irradiation of light beam irradiated by the light source device 211 to the optical component casing 25 , thereby enhancing cooling efficiency of the optical component. Further, the intensity of the optical component casing 25 can be maintained.
(1-8-3) Since the various optical components 212 to 215 , 221 to 223 and 231 to 234 are fixed on the optical component casing 25 with the positioning members 253 , a member such as a holder frame for holding the optical components 212 to 215 , 221 to 223 and 231 to 234 can be omitted, thereby reducing the production cost when the optical unit 2 is manufactured.
(1-8-4) The grooves 253 A 1 are formed on the end of the first positioning members 253 A. The first positioning members 253 A are inserted to the inside through the holes 251 A formed on the lateral side of the container 25 A so that the grooves 253 A 1 abuts on the outer peripheries of the optical components 212 to 215 , 231 and 233 to suspend them. Accordingly, the first positioning members 253 A can easily and accurately position the optical components 212 to 215 , 231 and 233 .
(1-8-5) Since the positions of the optical components 212 to 215 , 231 and 233 are fixed on the optical component casing 25 with the outer peripheries of the optical components 212 to 215 , 231 and 233 abutting on the grooves 253 A 1 of the first positioning members 253 A, the first positioning members 253 A reduce an external force so that the positions of the optical components 212 to 215 , 231 and 233 can be fixed on the optical component casing 25 without displacement.
(1-8-6) The hole 251 A formed on the lateral side of the container 25 A is formed by cutting and folding the part of the lateral side inside the container 25 A, and the cut and folded part of the lateral side defining the support portion 251 K for supporting the first positioning member 253 A. Accordingly, the shift of the first positioning members 253 A accompanied with the shift of the optical components 212 to 215 , 231 and 233 on account of the surface tension of the ultraviolet curing adhesive can be smoothly performed, thus accurately positioning the optical components 212 to 215 , 231 and 233 . Further, since the part of the lateral side of the container 25 A is cut and folded, the hole 251 A and the support portion 251 K can easily be formed. Furthermore, by the first positioning members 253 A and the support portions 251 K for supporting the first positioning members 253 A, the positions of the optical components 212 to 215 , 231 and 233 can be securely fixed.
(1-8-7) The second positioning member 253 B includes the mount 253 B 1 , the pair of plate members 253 B 2 and the spacers 253 B 3 . The dichroic mirrors 221 and 222 are arranged between the pair of plate members 253 B 2 in an inclined manner relative to the pair of plate members 253 B 2 , and spacers 253 B 3 are interposed between the respective members defined by the left and right ends of the dichroic mirrors 221 and 222 , and the plate members 253 B 2 . Accordingly, after the positions of the dichroic mirrors 221 and 222 are adjusted, the dichroic mirrors 221 and 222 can easily be positioned at the predetermined positions on the illumination optical axis of the light beam irradiated by the light source device 211 by the spacers 253 B 3 .
(1-8-8) When the dichroic mirrors 221 and 222 are housed in the component housing 251 of the container 25 A, the dichroic mirrors 221 and 222 are arranged on the second positioning members 253 B in advance, so that the second positioning members 253 B in which the dichroic mirrors 221 and 222 are arranged are housed in the component housing 251 . Accordingly, as compared to that the dichroic mirrors 221 and 222 are directly housed in the component housing 251 with the various optical components being closely arranged, the dichroic mirrors 221 and 222 can easily and accurately be housed in the component housing 251 .
(1-8-9) Since the dichroic mirrors 221 and 222 are arranged in the second positioning members 253 B, even when the profiles of the dichroic mirrors 221 and 222 are changed, the profile of the container 25 A is not necessary to be changed, but the plate members 253 B 2 of the second positioning members 253 B can correspond by changing the adjacent distances thereof.
(1-8-10) In the plate member 253 B 2 , the part of the end is cut and folded toward the plate member 253 B 2 opposite thereto in a triangular shape, which serves as the support portion 253 B 4 for supporting the spacer 253 B 3 . Accordingly, the shift of the spacers 253 B 3 accompanied with the shift of the dichroic mirrors 221 and 222 on account of the surface tension of the ultraviolet curing adhesive can be smoothly performed, thus accurately positioning the dichroic mirrors 221 and 222 by the spacers 253 B 3 . Further, by the spacers 253 B 3 and the support portions 253 B 4 , the positions of the dichroic mirrors 221 and 222 can be securely fixed.
(1-8-11) Since the spacers 253 B 3 are formed in a triangular prism, with the spacers 253 B 3 interposed between the plate members 253 B 2 and the left and right ends of the dichroic mirrors 221 and 222 , the inclined direction of the slanted face of the triangular prism is configured to be the approximately same direction as the inclined direction of the dichroic mirrors 221 and 222 . Accordingly, the spacers 253 B 3 can securely be abut on the left and right ends of the dichroic mirrors 221 and 222 . Therefore, the spacers 253 B 3 can accurately position the dichroic mirrors 221 and 222 . Further, the fixed state of the dichroic mirrors 221 and 222 on the optical component casing 25 can securely be mai