(12) United States Patent
`Saccoman no et al.
`
`USOO6428198B1
`(10) Patent No.:
`US 6,428,198 B1
`(45) Date of Patent:
`Aug. 6, 2002
`
`(54) DISPLAY SYSTEM HAVING A LIGHT
`SOURCE SEPARATE FROMA DISPLAY
`DEVICE
`
`(75) Inventors: Robert J. Saccomanno, Montville;
`Ivan B. Steiner, Ridgewood; Michael
`G. Biemer, Lincoln Park, all of NJ
`(US)
`(73) Assignee: AlliedSignal Inc., Morristown, NJ (US)
`(*) Notice:
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`(21) Appl. No.: 09/346,253
`(22) Filed:
`Jul. 1, 1999
`Related U.S. Application Data
`(60) Provisional application No. 60/091.981, filed on Jul. 7,
`1998.
`(51) Int. Cl. ............................ G09F 13/18: F12V 7/08
`(52) U.S. Cl. ......................... 362/559; 362/26; 362/561;
`362/558; 362/554; 362/552
`(58) Field of Search .......................... 362/26, 559, 561,
`362/558,554, 552, 583,560
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`3,195.405 A * 7/1965 Clarke et al. ............... 362/552
`4,233,650 A * 11/1980 Hagner et al. ...
`... 362/552
`4.915,479 A
`4/1990 Clarke ........................ 362/559
`(List continued on next page.)
`OTHER PUBLICATIONS
`Mirror Imaging Systems, Kingslake, Rudolf,"Optical Sys
`tem. Design,” Academic Press, 1983, pp. 245-253.
`Society of Automotive Engineers Paper 970254, Compari
`son of Dual Focus Collector Schemes for Fiber Systems,
`Feb. 1997, W. J. Cassarly et al.
`
`Society of Automotive Engineers Paper 981197, Changes in
`Angular and Spatial Distribution Introduced into Fiber Optic
`Headlamp Systems by the Fiber Optic Cables, Feb. 1998,
`Cassarly et al.
`Society of Automotive Engineers Paper 1999-01-0304,
`Fiber Optic Lighting: The Transition from Specialty Appli
`cations to Mainstream Lighting, Mar., 1999, Cassarly, et al.
`Paper given at The 8” International Symposium on the
`Science and Technology of Light Sources (L-S-8),
`Advances in Fiber Optics: Fiber Applications Move into the
`Mainstream, Sep. 1998, Davenport et al.
`Society of Automotive Engineers Paper 960490, Uniform
`Light Delivery Systems; Feb. 1996, Cassarly et al.
`Society of Automotive Engineers Paper 1999-01-0386,
`Remote HID Headlamp Systems, Mar. 1999, Dassanayake
`et al.
`Society of Automotive Engineers Paper 980877, HID
`Driven Focus-less Optics System for Complete Automotive
`Distributed Lighting Systems, Feb. 1998, Hulse et al.
`Primary Examiner Sandra O'Shea
`Assistant Examiner Peggy A Neils
`(74) Attorney, Agent, or Firm-Loria B. Yeadon
`(57)
`ABSTRACT
`High luminance display devices, typically utilized in appli
`cations requiring Sunlight readability, require unique design
`methodologies as the thickness approaches a maximum of
`one-inch. The present invention relates to a high intensity
`light generation engine and associated light transmission
`apparatus for transmitting the light generated by the engine
`to a remote location. The invention is especially applicable
`for use in constructing a back lighted display, Such as a
`liquid crystal display (LCD), of minimal thickness, i.e.,
`one-inch or less. A display of minimal thickness is achieved
`by Separating a light Source and other peripherals from the
`display device, using a remote enclosure. Such a display is
`most Suited for use in high ambient lighting conditions
`where space is at a premium, Such as in the cockpit of an
`aircraft.
`
`36 Claims, 24 Drawing Sheets
`
`10
`ELLPSODAL
`MIRRORS
`(1 OF8)
`
`20
`
`(8INPUTS, ONE OUTPUT)
`f
`12 LIGHT SOURCE
`42
`40
`30
`FERRULE /DIMMER HOMOGENIZER
`50
`FIBER OPTIC CABLE
`(1 INPUT 33 OUTPUTS)
`
`5
`-
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`
`
`
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`46
`
`TURN-THE-CORNER
`PRISMASSY.72
`
`
`
`
`
`a?
`
`DISPLAY
`
`O - O
`
`
`
`8O
`
`70
`WAVEGUIDE (LIGHTEXITSNORMALTOPAGE
`
`; v 50
`; (CATO
`SELEMENTASSEMBLY
`ARRAYOF33
`A
`
`SEC et al. v. MRI
`SEC Exhibit 1029.001
`IPR 2023-00199
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`US 6,428,198 B1
`Page 2
`
`U.S. PATENT DOCUMENTS
`
`5,050.946 A 9/1991 Hathaway et al. ............ 385/33
`5,136,480 A * 8/1992 Pristash et al. ..
`... 362/26
`5,146,354 A 9/1992 Plesinger ......
`... 359/49
`5,321,586 A * 6/1994 Hege et al. ...
`... 362/554
`5,341,445 A * 8/1994 Davenport et al.
`... 362/559
`5,414,600 A 5/1995 Strobi et al. ..
`... 362/32
`5,416,669 A * 5/1995 Kato et al. .
`362/26
`5,430,634 A 7/1995 Baker et al.
`... 362/32
`5,436,805. A * 7/1995 Hsu et al. ..
`... 362/559
`5,506,924 A
`4/1996 Inoue ......................... 385/129
`
`5,555,329 A 9/1996 Kuper et al. .................. 385/36
`5,560,699 A 10/1996 Davenport et al. ........... 362/32
`5,634,708 A
`6/1997 Koie et al. .................... 362/26
`5,671994. A * 9/1997 Tai et al. .............
`362/559
`5,690,408 A * 11/1997 De La Pena et al.
`... 362/26
`5,692,091. A 11/1997 Cassarly et al. .....
`385/146
`5,774,608 A
`6/1998 Allen et al. ................... 385/39
`5,791,756 A * 8/1998 Hulse et al. ...
`... 362/559
`5,836,667 A 11/1998 Baker et al. ...
`... 362/32
`5,982,974 A 11/1999 Davis ......................... 362/552
`* cited by examiner
`
`
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`SEC et al. v. MRI
`SEC Exhibit 1029.002
`IPR 2023-00199
`
`

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`U.S. Patent
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`Aug. 6, 2002
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`Sheet 1 of 24
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`US 6,428,198 B1
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`SEC et al. v. MRI
`SEC Exhibit 1029.003
`IPR 2023-00199
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`U.S. Patent
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`Aug. 6, 2002
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`FIG. 1B
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`SEC et al. v. MRI
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`Aug. 6, 2002
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`SEC Exhibit 1029.005
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`U.S. Patent
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`Aug. 6, 2002
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`FIG. 2A
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`SEC et al. v. MRI
`SEC Exhibit 1029.006
`IPR 2023-00199
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`SEC et al. v. MRI
`SEC Exhibit 1029.007
`IPR 2023-00199
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`U.S. Patent
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`Aug. 6, 2002
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`U.S. Patent
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`SEC et al. v. MRI
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`SEC et al. v. MRI
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`U.S. Patent
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`SEC Exhibit 1029.013
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`U.S. Patent
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`Aug. 6, 2002
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`Aug. 6, 2002
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`U.S. Patent
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`US 6,428,198 B1
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`SEC et al. v. MRI
`SEC Exhibit 1029.020
`IPR 2023-00199
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`SEC et al. v. MRI
`SEC Exhibit 1029.021
`IPR 2023-00199
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`Aug. 6, 2002
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`SEC et al. v. MRI
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`U.S. Patent
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`Aug. 6, 2002
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`U.S. Patent
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`Aug. 6, 2002
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`Aug. 6, 2002
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`IPR 2023-00199
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`

`1
`DISPLAY SYSTEM HAVING ALIGHT
`SOURCE SEPARATE FROMA DISPLAY
`DEVICE
`
`RELATED APPLICATION
`This application claims priority from U.S. Provisional
`Patent Application Serial No. 60/091,981 entitled, “Flat
`Panel Display System”, filed on Jul. 7, 1998. The contents
`of U.S. Provisional Patent Application Serial No. 60/091,
`981 are fully incorporated herein by reference.
`FIELD OF THE INVENTION
`The present invention relates to a high intensity light
`generation engine and associated light transmission appara
`tus for transmitting the light generated by the engine to a
`remote location. The invention is especially applicable for
`use in constructing a back lighted display, Such as a liquid
`crystal display (LCD), of minimal thickness. In particular,
`the invention achieves a display of minimal thickneSS by
`Separating the light Source from the display mechanism.
`Such a display is most Suited for use in high ambient lighting
`conditions where space is at a premium, Such as in the
`cockpit of an aircraft. The inventive light generation engine
`and associated light transmissive apparatus may also be used
`for other applications besides illuminating a display, Such as
`for projection displays, ground vehicle instrument displayS,
`automotive lighting (Such as headlights, tail lights, panel
`lights, map lights, and dome lights), airport runway lights,
`aircraft interior lighting, and Street lights.
`BACKGROUND OF THE INVENTION
`Typically, high luminance displays (e.g. those used in
`avionics applications) are based upon transmissive liquid
`crystal displays (LCDs) with one or more fluorescent lamps.
`When packaged in a reflecting cavity and Supplemented by
`light control films, Such lamps can be driven at Sufficient
`power levels to generate enough lumens to produce well in
`excess of 200 fill out of the transmissive LCD. Typically,
`these displays are at least three inches thick when combined
`with a minimal amount of electronics. AS more electronics
`are added to increase functionality, display thickness
`increases correspondingly. Additionally, for avionics
`applications, the active display area must occupy a large
`percentage of the overall enclosure area Since instrument
`panel Space is at a premium. This further complication
`increases packaging density, and as the packaging density
`increases, the thermal design obviously becomes more criti
`cal. Beyond approximately 0.1 watts per cubic inch, active
`cooling should be employed, which is generally fan-based,
`thus further increasing Volume.
`There exists a desire to drive the display thickness to leSS
`than one inch for many applications, Such as avionics. In
`regard to avionic applications, this would facilitate upgrad
`ing a cockpit with new displays requiring minimal modifi
`cation of the cockpit instrument panel and Surrounding
`Structural members. Obsolete displayS may be removed and
`replaced by new displays, including those which relate to the
`present invention, that Simply attach over the existing instru
`ment panel. Most avionics displays protrude in front of an
`instrument panel by no more than one inch. This limit is due
`to Several factors, Such as to preclude one display from
`Shadowing another, to avoid protruding into the ejection
`envelope in fighter and attack planes, and to avoid interfer
`ences with the controls used by a crew member (Such as, for
`example, limiting fall travel of the control yoke).
`To achieve high luminance, high contrast, and high reso
`lution in a conventional display intended for high ambient
`
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`US 6,428,198 B1
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`2
`lighting conditions, considerable display thickness and rela
`tively high intensity light Sources are required. However,
`thick displays and the large amounts of heat generated by
`high intensity lamps are adverse to certain applications, Such
`as those for the cockpit of an airplane.
`In View of the foregoing, this invention provides a display
`System in which the light Source is located remotely from a
`display device, Such as an LCD, and its backlight. By
`Separating the lamp, driving electronics, and other compo
`nents from the display device and locating them remotely,
`Space requirements can be satisfied without violating the
`Severe envelope restrictions for aircraft cockpit-Suitable
`display System elements.
`This invention also provides a high intensity light engine
`comprising a light Source and a light collection assembly,
`and an optical transmission apparatus for transmitting the
`light to a remote location, Such as to a display device.
`SUMMARY OF THE INVENTION
`The present invention is directed to a high intensity light
`generation engine and associated light transmission appara
`tus for transmitting the light generated by the engine to a
`remote location. The invention is especially applicable for
`use in constructing a back lighted display, Such as a liquid
`crystal display (LCD), of minimal thickness, i.e., one-inch
`or less. A display of minimal thickneSS is achieved by
`Separating the light Source and other peripherals from the
`display device. Accordingly, the light Source and other light
`transmissive apparatus are comprised in a remote enclosure.
`Such a display is most Suited for use in high ambient lighting
`conditions where space is at a premium, Such as in the
`cockpit of an aircraft. The inventive light generation engine
`and asSociated light transmissive apparatuS may also be used
`for other applications besides illuminating a display, Such as
`for projection displays, ground vehicle instrument displayS,
`automotive lighting (Such as headlights, tail lights, panel
`lights, map lights, and dome lights), airport runway lights,
`aircraft interior lighting, and Street lights.
`In accordance with an illustrative embodiment of this
`invention, a System for illuminating a display, Such as a flat
`panel display (i.e. an LCD) is provided. Several of the
`systems functional elements are illustratively listed below:
`A light Source for generating light.
`A light collection assembly for collecting the light gen
`erated by the light Source and for providing one or more
`light outputs. The light collecting assembly comprises
`at least one ellipsoidal mirror, and preferably eight
`ellipsoidal mirrors, for reflecting the light generated
`from the light Source to corresponding exit port holes.
`A light guide assembly for collecting light from the light
`output(s) and transmitting it to a common exit port.
`An optional dimmer for providing a controllable variable
`attenuation of the light emitted by the light guide
`assembly common exit port.
`A homogenizer for capturing potentially non-uniform
`light from the optional dimmer or, alternatively,
`directly from the light guide assembly common exit
`port, and for providing a uniform irradiance across the
`homogenizer exit port area. The irradiance acroSS the
`exit port area generated by the homogenizer also has
`Spectrally and angularly uniform characteristics. Note
`that the homogenizer is preferably tapered, where its
`input port is larger than its output port.
`A fiber optic cable assembly for capturing light from the
`Single homogenizer exit port and distributing it to
`multiple exit ports.
`
`SEC et al. v. MRI
`SEC Exhibit 1029.027
`IPR 2023-00199
`
`

`

`US 6,428,198 B1
`
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`A collimator element assembly. Each collimator element
`captures light from a corresponding light distribution
`means exit port and projects light with improved col
`limation.
`A turn-the-corner assembly that captures the collimated
`light projected by the collimator elements and reverses
`its propagation direction in a Space-efficient manner
`while maintaining collimation.
`A waveguide backlight that captures the collimated light
`from the turn-the-corner assembly and projects it in the
`direction normal to the backlight exit face.
`A liquid crystal display (LCD) that transmits the colli
`mated light projected by the backlight while modulat
`ing it spatially and, in non-monochrome applications,
`Spectrally acroSS the LCD area to form an image.
`A view Screen that transmits the light projected by the
`LCD while decollimating (or diffusing) it to project the
`LCD image to be seen over a wide range of viewing
`angles.
`AS an aspect of this embodiment, the System further
`comprises one or more optical light pipes (e.g., a Solid
`cylindrical rod or, alternatively, a Square or rectangular croSS
`Section Solid rod), where each light pipe is coupled to a
`respective exit port hole of the light collecting assembly. The
`light pipes reduce heat concentrations and ultraViolet
`radiation, generated by the light collecting assembly, that
`would otherwise be fully dissipated in the light guides
`leading to the homogenizer. The light pipes are preferably
`made of a visible light transparent heat-tolerant material,
`Such as glass, fused Silica or Sapphire. Further, each light
`pipe is preferably coated with either a dielectric infrared
`reflecting coating, an ultraViolet reflecting coating or a
`combination thereof.
`As a further aspect of this embodiment, the waveguide has
`a bottom Surface having either a Sawtooth or a truncated
`Sawtooth Surface for directing light out of the waveguide at
`predetermined angles based on the Size and shape of the
`Sawtooth and truncated Sawtooth Surfaces.
`AS an additional aspect of this embodiment, the System
`includes an apparatus for redirecting light, Such as a turn
`the-corner prism assembly, positioned preceding the
`waveguide. Illustratively, this assembly has one or more
`prisms, where each prism includes an input Surface, an
`output Surface, and in the case where there are a plurality of
`prisms, an interface between the prisms (Such as a thin
`adhesive or glue gap) to improve the light-handling effi
`ciency of the assembly. In particular, the adhesive preferably
`has an index of refraction less than the index of refraction of
`the adjacent prisms.
`AS yet another aspect of this embodiment, the System
`includes an electro-mechanical dimmer for attenuating the
`light entering the homogenizer. The dimmer disposed imme
`50
`diately preceding the homogenizer entrance port is config
`ured to have a dimming ratio from 300:1 to 88,500:1. The
`dimmer comprises a pair of aperture plates, where each plate
`has a diamond-shaped aperture. One of these may include a
`filter therein. However, differently shaped apertures can also
`be configured to provide the same function.
`AS yet a further aspect of this embodiment, the System
`further includes an array of collimators, positioned imme
`diately preceding the turn-the-corner prism assembly, for
`collimating the homogenized light. Illustratively, the colli
`mator comprises an array of tapered cavities, where the
`array's tapered cavities have either round, Square, or trian
`gular croSS-Sections, or combinations thereof.
`BRIEF DESCRIPTION OF DRAWINGS
`The following detailed description, given by way of
`example and not intended to limit the present invention
`
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`solely thereto, will best be understood in conjunction with
`the accompanying drawings, where similar elements will be
`represented by the Same reference Symbol, in which:
`FIG. 1A is a block diagram of a flat panel display System
`in accordance with an embodiment of the present invention;
`FIG. 1B is a bottom perspective view of a portion of the
`flat panel display system of FIG. 1A in accordance with the
`present invention;
`FIG. 1C is a top perspective view of a portion of the flat
`panel display system of FIG 1A in accordance with the
`present invention;
`FIG. 2A is an exploded view of a portion of a flat panel
`display System including brackets and a remote enclosure in
`accordance with the present invention;
`FIG. 2B is a block diagram of a portion of the flat panel
`display System of FIG. 1A including other peripherals in
`accordance with the present invention;
`FIG. 2C is a bottom perspective View of a Special align
`ment washer in accordance with the present invention;
`FIG. 3 shows a dimmer device optionally utilized in the
`flat panel display system of FIG. 1A in accordance with the
`present invention;
`FIGS. 4A, 4B, and 4C are side elevation, isometric, and
`assembly views, respectively, of the light collecting assem
`bly of FIGS. 1B and 1C in accordance with the present
`invention;
`FIG. 5 is a lamp and cooling assembly of the flat panel
`display system of FIG. 1A in accordance with an embodi
`ment of the present invention;
`FIG. 6 is a lamp and cooling assembly of the flat panel
`display system of FIG. 1A in accordance with a further
`embodiment of the present invention;
`FIG. 7 is a lamp and cooling assembly of the flat panel
`display system of FIG. 1A in accordance with yet a further
`embodiment of the present invention;
`FIG. 8 is a perspective view of the homogenizer of the flat
`panel display system of FIG. 1A in accordance with the
`present invention;
`FIG. 9 illustrates an embodiment of a square collimator
`array of the flat panel display system of FIG. 1A in accor
`dance with an embodiment the present invention;
`FIG. 10A illustrates an embodiment of a detail of the array
`of collimator elements in the flat panel display System of
`FIG. 1A in accordance with a preferred embodiment of the
`present invention;
`FIG. 10B illustrates an embodiment of a detail of the array
`of collimator elements in the flat panel display System of
`FIG. 1A in accordance with an alternate embodiment of the
`present invention;
`FIG. 11 illustrates an embodiment of a packed triangular
`air cavity collimator array of the flat panel display System of
`FIG. 1A in accordance with a further embodiment of the
`present invention;
`FIG. 12 illustrates an embodiment of a turn-the-corner
`assembly of the flat panel display system of FIG. 1A in
`accordance with an embodiment the present invention;
`FIG. 13 illustrates the embodiment of the turn-the-corner
`assembly of FIG. 12 including a waveguide in accordance
`with an embodiment the present invention;
`FIG. 14 illustrates a waveguide of the flat panel display
`system of FIG. 1A in accordance with the present invention;
`FIG. 15 illustrates a bottom surface of a waveguide
`having a Sawtooth Surface of the flat panel display System of
`FIG. 1A in accordance with an embodiment the present
`invention;
`
`SEC et al. v. MRI
`SEC Exhibit 1029.028
`IPR 2023-00199
`
`

`

`S
`FIG. 16 illustrates a bottom surface of a waveguide
`having a truncated Sawtooth Surface of the flat panel display
`system of FIG. 1A in accordance with a further embodiment
`the present invention;
`FIG. 17 illustrates a conventional bottom Surface of a
`waveguide having a pure Stepped or truncated Surface;
`FIG. 18 is a side perspective view of a portion of the flat
`panel display System of FIG. 1A including a cylindrical glass
`rod and ferrule in accordance with the present invention; and
`FIG. 19 illustrates the cylindrical glass rod of FIG. 18 in
`accordance with the present invention.
`DETAILED DESCRIPTION OF THE
`INVENTION
`In an illustrative embodiment, the present invention is a
`high luminance, one-inch thick display System, although
`display Systems of other thicknesses may be utilized as well.
`In accordance with the invention, the Source of illumination
`is located remotely from the display device, Such as an LCD
`and its accompanying waveguide, View Screen, and back
`light (if the display device is transmissive). The display
`device may be emissive, transmissive or reflective. The
`display is described below from the optical and mechanical
`point of view.
`A Schematic block diagram of a flat panel display System
`5 in accordance with the present invention is shown in FIG.
`1A, while portions of display system 5 are illustrated in
`FIGS. 1B, 1C, 2A and 2B. As will be described, Such
`portions comprise peripherals that will be included in a
`remote enclosure, i.e., away from the display device. It
`should be understood that display system 5 is schematic in
`nature and the relative sizes, positions, and shapes of the
`components in the diagram are merely for ease of discus
`SO.
`As shown in FIGS. 1A-C and 2A and B, display system
`5 includes a light collecting assembly 20, which will be
`described in greater detail with reference to FIGS. 4A, 4B
`and 5-7, for focusing light from light source 12. Generally,
`light collecting assembly 20 is designed to deliver visible
`light to its exit ports, although assembly 20 may be designed,
`alternatively, to deliver radiant fluxes, Such as infrared light,
`ultraViolet light, and microwaves. Illustratively, light col
`lecting assembly 20 is approximately 3" by 4" by 3.6" high,
`and has a collection efficiency exceeding 70%. Its functional
`elements include an enclosed concentrated light Source 12,
`Such as a Small-arc high intensity discharge (HID) lamp and
`a lamp enclosure comprising ellipsoidal mirrorS 10. The
`light source 12 may be powered by a 270 W arc lamp, which
`may have an arc gap of 1.4 mm, although other lamp powers
`and/or arc gaps can be utilized. In addition, light Source 12,
`except for electrode Shadowing effects, is preferably a
`Substantially omnidirectional radiator. Thus, the collecting
`assembly 20 can preferably provide two or more light
`outputs, by Segmenting the output of omnidirectional light
`Source 12.
`As best seen in FIGS. 1B, 1C and 2A, the ellipsoidal
`mirror 10 are Supported by a plurality of L-shaped Support
`brackets 115. Each wing of the “L” is approximately 0.9"
`wide and 2.25" high. Specifically, FIGS. 1B and 1C show an
`assembly of four L-shaped support brackets 115, while FIG.
`2A shows only two of the existing four brackets 115. As
`shown in FIG. 2A, each bracket has a pair of clearance
`through-holes (one on each side of the “L”) 117, for allow
`ing protrusion of the end ferrule of each fiber cable leg 25,
`and a pair of tapped holes 119 for Securing each protruding
`fiber cable leg to its respective adjuster 120 by means of
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`US 6,428,198 B1
`
`6
`thumb screw clamp 18 shown in FIGS. 1B and 1C. Through
`hole 117 is approximately 0.36" in diameter and tapped hole
`119 is approximately 0.19" in diameter. Further, light source
`12 and the ellipsoidal mirrors are Supported by top and
`bottom hub plates 16, 14 each having approximate dimen
`sions of 3" by 3.9" by 0.25" thick and having a diameter of
`4.93". Further, the height from the top of top hub plate 16 to
`the bottom of bottom hub plate 14, when supporting the
`mirrors, is approximately 2.75".
`To ensure that ellipsoidal mirrors 10 and mirror edge slots
`112, which form exit port holes for assembly 20, are
`properly aligned, it is desirable to build a Suitable Set of
`accurate datum Surfaces into the design of the assembly.
`Efficient light extraction from the light Source depends on
`Such proper alignment. In FIG. 2A, the exploded view of
`light collecting assembly 20 illustrates how various elements
`of the light engine are assembled and illustrates the design
`of the datum Surfaces desired for alignment.
`With reference to FIGS. 2A and 4A-4C, there are illus
`tratively four ellipsoidal mirror 10. The top and bottom of
`the four ellipsoidal mirror 10 have cylindrical surfaces that
`engage cylindrical hubs of hub plates 16 and 14, respec
`tively. The mirrors 10 are securely held against hub plates 14
`and 16 means of garter Springs 126 that engage matching
`torriodal grooves 127 ground into the backs of mirrors 10.
`The top and bottom of the light source 12 are held by means
`of cylindrical clamp assembly 28, which is inserted into
`circular holes in hub plates 14 and 16. These holes are
`concentric with the hubs and provide Sufficient clearance for
`alignment of the light Source 12 with a common focal point
`located in the center of the assembly 20 and coincident with
`the common axis of both hubs.
`AS Shown in FIGS. 2A and 2C, a special alignment washer
`23 is disposed around the hub of hub plate 16. The top of this
`washer 23 is flat to engage the flat bottom surface of hub
`plate 16 while the bottom face of this washer has a conical
`taper to match the top faces of mirrorS 10. Clocking align
`ment of each mirror 10 about the hub axis is provided by
`notches 140 in the top corner edges of each mirror Section
`(see FIGS. 4A-4C). Notches 140 have accurate reference
`datum Surfaces that are normal to the bottom face of hub
`plate 16. There are four raised key protrusions 21 from the
`bottom conical face of washer 23. Protrusions 21 have eight
`accurate reference faces designed to engage the correspond
`ing reference datum Surfaces of the four mirrorS 10 notches.
`In order to provide clocking alignment of mirror edge slots
`112 with corresponding through-holes 117 of L-shaped
`support brackets 115, a pin through-hole 29 is provided in
`washer 23 for engaging a corresponding pin in hub plate 16.
`The four L-shaped Support brackets and their eight through
`holes 117 are accurately positioned with respect to the hub
`plate 16 pin So as to ensure proper alignment of through
`holes 117 with mirror edge slots 112.
`Eight relatively tiny coil springs 38 are inserted into
`corresponding receptacles 39 in bottom hub plate 14 adja
`cent to the hub. The conical bottom faces of mirrors 10 each
`engage two of these Springs. Thus each mirror Section is
`Spring-loaded toward top hub plate 16. This spring-loading
`action ensures that the top and bottom interfaces of washer
`23 between the mirrors 10 top conical faces and top hub
`plate 16 is kept in intimate contact with each other.
`The Spring-loading action of coil springs 38 and of garter
`Springs 126 is an effective means of maintaining critical
`alignments in the presence of thermal dimensional distor
`tions caused by heat generated by the lamp. This Spring
`loading method avoids producing Stresses at the glass mirror
`
`SEC et al. v. MRI
`SEC Exhibit 1029.029
`IPR 2023-00199
`
`

`

`US 6,428,198 B1
`
`7
`interfaces that would crack the mirrors. Such stresses exist
`in conventional alignment methods that do not accommo
`date thermally-induced dimensional distortions.
`In regard to fabrication, the unit cost of molding accurate
`glass Surfaces is less than the cost of grinding them (and, of
`course, less than the cost of grinding and polishing them).
`Therefore, the critical Surfaces of mirrors 10 are preferably
`molded. These molded mirror surfaces include the ellipsoi
`dal mirror Surfaces, the top and bottom cylindrical hub
`interface Surfaces, the top and the bottom conical interface
`Surfaces, the notched top mirror clocking interface Surfaces,
`and the mirror 10 edge slot Surfaces. To facilitate the glass
`molding process, all molded Surfaces are designed to have
`draft angles if they are not otherwise shaped and/or oriented
`to accommodate release from the mold. For example, the top
`and bottom mirror edges are preferably configured to be
`conical instead of flat in order to accommodate easy mold
`release. For the same reason, the mirror edge slots 112 are
`preferably designed to have a draft angle.
`FIGS. 4A, 4B, and 4C are side elevation, isometric, and
`assembly views, respectively, of the mirrors 10 of light
`collecting assembly 20 shown in FIGS. 1B and 1C. As
`shown in FIG. 4B, each ellipsoidal mirror 10 comprises two
`ellipsoidal mirror sections 110, which is preferable for ease
`of manufacture. Accordingly, each ellipsoidal mirror Section
`110 is positioned in such a way so as to have a first focal
`point common to all eight mirror sections 110 substantially
`centered on the arc of light Source 12. Further, each ellip
`Soidal mirror Section 110 has a Second unique focal point,
`each of which is Substantially centered on or near a respec
`tive mirror edge slot 112 that provides a cylindrical rod
`entrance port 125 (see FIG. 4C) for a corresponding cylin
`drical rod 138 (to be described in detail below). Thus, each
`ellipsoidal mirror focuses the light it intercepts from the arc
`on the corresponding cylindrical rod entrance port 125
`located at or near the Second focal point of this mirror. Note
`that each mirror edge slot 112 is aligned with a respective
`bracket port hole 117 shown in FIGS. 1B and 1C.. Each
`cylindrical rod entrance port 125 is, e.g., 4 mm