OPTICAL FILTER AND METHOD FOR PREPARING SAME

Abstract

A filter, having a first filter material and second filter material, the first and second filter materials having different light attenuation properties and being in mutual contact along an interface surface, a cross-section of which has a curved line. Additionally, a method for preparing a filter, by: combining a first surface and an element to form a moulding cavity, delimited by the surface and by a moulding surface of the element; inserting a first material in liquid state; allowing the first material to solidify; removing the element to form a second moulding cavity, delimited by a second part of the surface and by the solidified first material; and inserting a second material in the second moulding cavity.

Claims

1-20. (canceled)

21. A graded optical filter having a substantially planar main body, the optical filter comprising a first filter material and a second filter material present in respective regions of said main body, the first filter material and the second filter material having substantially the same real part of their refractive index and different light attenuation properties, wherein the first filter material and the second filter material are in mutual contact along an interface surface, and wherein a cross-section of said interface surface along a plane perpendicular to said main body comprises a curved line.

22. The optical filter according to claim 21, wherein a combined thickness of the first filter material and the second filter material is preferably at least 0.5 mm.

23. The optical filter according to claim 21, wherein said curved line is shaped so as to provide the filter with continuous transitions between gradient levels.

24. The optical filter according to claim 21, wherein the difference between the real part of the refractive index of said first filter material and the real part of the refractive index of said second filter material is less than 0.002.

25. The optical filter according to claim 21, wherein said curved line is described by y=a ln(bx), where x and y are coordinates in said plane, the x-axis being parallel to said main body and the y-axis being perpendicular to said main body, and a and b are scaling constants.

26. The optical filter according to claim 21, wherein the material thicknesses are chosen to provide a pre-defined filter transmission.

27. The optical filter according to claim 21, wherein at least one of said first filter material and said second filter material is perceived homogeneous for the intended radiation.

28. The optical filter according to claim 21, wherein means for increasing the absorption coefficient have been added to at least one of said first filter material and said second filter material.

29. The optical filter according to claim 21, wherein at least one of said first filter material and said second filter material comprises a resin.

30. The optical filter according to claim 21, further comprising a first transmitting sheet covering a first side of said main body.

31. The optical filter according to claim 21, further comprising a second transmitting sheet covering a second side of said main body.

32. The optical filter according to claim 30, wherein the first transmitting sheet and/or the second transmitting sheet are glass plates or transparent polymers.

33. A projection system comprising a plurality of projectors, wherein each one of said plurality of projectors is equipped with an optical filter according to claim 21.

34. A method for preparing a graded optical filter, the method comprising: combining a first planar surface and a moulding element to form a first moulding cavity, said first moulding cavity being delimited on one side by a first part of said first planar surface and along an edge by a moulding surface of the moulding element, inserting a first material in said first moulding cavity in liquid state, allowing the bulk of said first material to solidify, removing the moulding element so as to produce a second moulding cavity in the space previously occupied by the moulding element, said second moulding cavity being delimited on one side by a second part of said first planar surface and along an edge by said solidified first material, and inserting a second material in the second moulding cavity in liquid state; wherein the first material and the second material have substantially the same real part of their refractive index and different light attenuation properties; and wherein a cross-section of said moulding surface along a plane perpendicular to said first planar surface comprises a curved line.

35. The method according to claim 34, wherein a combined thickness of the first filter material and the second filter material is preferably at least 0.5 mm.

36. The method according to claim 34, wherein said curved line is shaped so as to provide the filter with continuous transitions between gradient levels.

37. The method according to claim 36, wherein the outer boundaries of said first material are left partly non-solidified during the removing of the moulding element.

38. The method according to claim 34, wherein the first planar surface is a first transmitting sheet, which becomes part of the optical filter, and/or the method further comprises placing a second transmitting sheet on top of the first material and the second material, parallel to the first planar surface, said second transmitting sheet becoming part of the optical filter.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0038] Embodiments of the present invention will now be described in detail with reference to the accompanying drawings, in which:

[0039] FIG. 1 is an illustration of a display system;

[0040] FIG. 2 is an illustration of a display system;

[0041] FIG. 3 is an illustration of a display system with blended images;

[0042] FIG. 4 provides examples of dither patterns;

[0043] FIG. 5 represents the transmission curve of a material slab according to an embodiment of the present invention;

[0044] FIG. 6 is an illustration of a projector with two types of filters according to an embodiment of the present invention;

[0045] FIG. 7 is an illustration of a filter according to an embodiment of the present invention;

[0046] FIG. 8 is an illustration of a filter according to an embodiment of the present invention;

[0047] FIG. 9 represents a process scheme according to an embodiment of the present invention;

[0048] FIG. 10 illustrates steps of an embodiment of the method according to the present invention; and

[0049] FIG. 11 illustrates steps of another embodiment of the method according to the present invention.

DETAILED DESCRIPTION

[0050] The drawings are schematic illustrations and non-limiting and should not be interpreted to represent an exact scale of the physical objects. Cross-sections of the three-dimensional filter have been used to facilitate the illustration, but this two-dimensional representation should not be seen as a limitation for the filter. The interface of the filter can be non-linear or irregular in all directions. The present invention is not limited to the disclosed embodiments. In the whole description, the same drawing numerals are used for the same elements of the present invention throughout the text. It should be understood that the term “comprising” used in the claims should not be interpreted as being restricted to the means listed thereafter, but should be interpreted as specifying the presence of the stated features and does not preclude the presence or additions of one or more features.

[0051] Multichannel projector displays are display systems that make use of at least two projectors to form an image. FIG. 1 shows an example of a multichannel projection display system where the dashed lines represent the beam 30 from one projector 10, displayed onto the screen 20.

[0052] FIG. 2 illustrates how two projectors 10 are aligned so that their images are stitched next to each other, in a) a top view and in b) a front view. Misalignments and lens errors may lead to a dark or bright seam 40 between the two images. It is therefore common to let the images partially overlap. In the overlap zone there will be contribution from more than one projector and the brightness will be too high. The erroneous brightness can be controlled in various ways; in principle this is done electronically or physically, the latter is preferred to maintain high contrast. An optical filter with a multiple of grey scales will provide a transmission gradient.

[0053] FIG. 3 shows a system using gradient filters 60 to achieve a flat brightness distribution 50. The smoothness of the filter transmission characteristic is determined by the number of grey scales. Most manufacturing techniques for making a customized grey scale filter are digital where the grey scales are achieved with dither patterns where a denser pattern will provide a darker grey level.

[0054] FIG. 4 gives some examples of dithering patterns with different density. However, the dither pattern can give rise to artefacts such as diffraction, scattering or reproduction of the dither pattern in the image. The contone- and halftone techniques in laser- and ink jet printers use dither patterns. An optical filter with a continuous tone of analogue or true grey scales is free from internal structure in order to avoid the above mentioned artefacts. The continuous tone technique refers to prints that are made of continuous transitions of tone and colour, rather than being composed of individual dots (“Photo Finish: the digital photographer's guide to printing, showing, and Selling Images”, Sybex, by J. Canfield, Tim Grey). There are several techniques to obtain such a filter. The dye sublimation technique is commonly used in photography. Dyes on a carrier are sublimated and migrate into a substrate. Disadvantages of this technique are limitations in maximum optical density (which in turn limits the contrast ratio) and a short life time. Additionally it's not straightforward to print directly on glass. Another method is high energy beam sensitive or HEBS™ filters. This technique is used in photolithographic applications among others. However, the grey tones are not colour neutral, and the electron beam writing process time sequential and not efficient for large areas. Further, the grey level patterns are written according to an analytical equation, which imposes limitations on blend filter designs.

[0055] The described brightness correction filter is not limited to be used for multi-display projection systems, but could also be used e.g. as backlight corrector for displays implemented with such lightning technology.

[0056] According to Lambert-Beer's law the transmission T of an absorptive neutral density layer can be expressed as

T=(1−R).sup.2 exp(−k*d)

ln(T/(1−R).sup.2)=−k*d

d=−ln(T/(1−R).sup.2)/k   (1)

[0057] Where R is the surface reflectance, k is the absorption coefficient [1/m] and d is the thickness [m] of the absorptive medium. This implies that for a medium with given absorption k and given reflection R, one can calculate the thickness d of the tinted material that is required to achieve a certain transmission. The surface reflectance R can be measured or calculated, hence we can derive a function for the thickness d that would give us a linear transmission gradient. It turns out that d exhibits a logarithmic behaviour. Thus, if the extinction coefficient of the filter material is known and a target transmission for providing a seamless image is known, the thickness profile of the filter material can be calculated. The transmission of each filter can be linear in the overlap zone, adding up to a flat brightness level as shown in FIG. 3.

[0058] FIG. 5 shows the incident light 70, a tinted wedge shaped medium 80, the transmitted light 90 and below the graph illustrating the corresponding thickness (in mm) 100 and the thickness profile 110 of the transmitting medium. The thickness profile 110 is given a logarithmic shape, creating a gradient in material thickness perpendicular to the axis of the light propagation. The incident light 70 will get differently absorbed so that the transmitted light 90 will have a linear gradient 100. Since an optical wedge contains optical power it gives rise to wave front distortion.

[0059] FIG. 6 a) shows how the light 85 transmitted from the logarithmically shaped edge of the filter is refracted from point A to point B. Thus, if the tinted material is non-linearly shaped it is advantageous to put a non-tinted material with the real part of the refractive index very close to that of the tinted material. The inventor has found that it is preferable if the difference in the real part of the refractive index of the two materials is smaller than 0.002 to avoid image artefacts. FIG. 8 b) shows how such a compound filter consisting of a tinted wedge shaped medium 80 and non-tinted material 120 forms a continuous gradient filter which refracts the light homogeneously across the filter.

[0060] Thus, with knowledge of the brightness profile of the images of a multiple projector system, the transmission profile of the filters can be decided. Knowing the transmission and the absorption coefficient of the filter material, the thickness of the filtering material can be calculated. It is also possible to make a custom made filter for each overlap zone of a multichannel display system. For a certain absorption coefficient of the filter material and for a desired output transmission, the material thickness for each pixel position is calculated using Lambert-Beer's law (1).

[0061] FIG. 7 shows an example of a composed filter where a non-tinted material 120 with the same (real) refractive index as the tinted wedge shaped medium 80 has been added in order to avoid refractive power of the filtering material. The interface between the two materials 80 and 120 has a logarithmic profile so that the transmission will be linear. Lambert-Beer's law (1) gives that the transmission is proportional to exp(−kd), d being the distance the light has travelled and k being the extinction coefficient of the medium the light travels through. More generally, the interface profile, which corresponds to the cross-section of the interface surface between the two different filter materials in a plane perpendicular to the main body of the filter, may be described by any desired curve. In particular, the interface surface may be any general curved surface.

[0062] In principle the transmission could be described by any function or shape. The linear case is an example of an embodiment that can be used to create a gradient filter for multichannel display systems. If the transmission is known, the thickness will be proportional to the logarithm of the transmission and to the extinction coefficient of the medium. In this way it is possible to obtain a target transmission with help of varying the thickness of the medium. It is important that there is a smooth and distinct interface between the two materials. The second material 120 is a means for avoiding refraction between the wedge-shaped tinted medium 80 and the surrounding medium (e.g. air) due to the difference in (real) refractive index between them. The transmission modulation is provided by the thickness of the wedge shaped tinted medium 80. The extinction coefficient of a material determines the amount of attenuation of light travelling through it. The interface should not contain any air inclusions or impurities to avoid scattering and other image artefacts.

[0063] The invention is however not limited to transmission control of visible light but can be extended to any material property and wavelength range of the involved radiation. Hereafter is meant with “filter material” the material that is performing some type of filtration of the radiation. A “clear material” is a material with no such filtration property but with the (real) refractive index substantially identical or very close to the filter material. An example of the two could be a tinted and a non-tinted version of the same material.

[0064] FIG. 8 illustrates an embodiment of the present invention where a) is a side view with the light propagation axis 130 and b) is a top view where the light propagation axis 130 is perpendicular to the plane of the paper. Glass slabs 140 and 145, referred to as “a” and “b” respectively, have anti-reflection layers 150 and encompass the filter material 80 and the clear material 120. The interface 110 is non-linear in all three dimensions.

[0065] An additive can be mixed into the material in order to further increase the maximum absorption level. This will not affect the lowest absorption level possible which can still be implemented with letting the wedge thin out to zero thickness. It is also possible to leave a certain thickness of the filtering material for obtaining the minimum absorption level. The non-flat shape of the material will refract the light, so a non-tinted version of the same material, or another material with substantially the same (real) refractive index, is added on top of the tinted profile. The combined piece will have flat parallel surfaces and will not refract the light. If the material is homogeneously tinted, there will be no internal structure that could give rise to diffraction or scattering.

[0066] In the present embodiments, a linear transmission gradient is considered for simplicity, but theoretically it is possible to realize arbitrary transmission gradients by calculating or measuring the system output brightness. This means that the filter can be tailored according to the brightness profile of the system it will be used in.

[0067] The present invention also pertains to a projection system comprising a plurality of projectors, wherein each one of said plurality of projectors is equipped with an optical filter as described above.

[0068] FIG. 9 illustrates a manufacturing method of an embodiment of the invention. The process comprises the below described steps.

[0069] In 160 contains preparation steps 170 and 180 that can be performed in any order. In 170 the desired transmission characteristics are obtained. Knowing the material extinction coefficient for the filter material to be used, the corresponding thickness profile is calculated, using for example Lambert-Beer's law (1). A mould is manufactured which can be a solid structure representing the negative of the calculated thickness profile. Or it can contain a cavity representing the calculated thickness profile. This can be done by a process based on for example 3D printing, extrusion, sintering or lamination or by any suitable subtractive or additive method that can provide an arbitrary shaped structure. An optionally step is to mix additives into the filtering material. The solution is then left to rest in a vacuum chamber to withdraw air bubbles introduced by the mixing. Air bubbles could cause scattering of the light and reduce the contrast. Especially air bubbles on the boundary of the filter material could result in locally incorrect thickness followed by an incorrect transmission level. The additives could be one that influence absorption, refraction, conductivity, colour, mechanical strength or any other desired property.

[0070] In 190, glass plates are put together and kept separated with a non-resilient spacer material with controlled thickness. This could for example be small rods of steel, ceramics or hard polymer or any other firm and non-reactive material. The glass plates are then fixed together with means for clamping.

[0071] In 200, the first filter material is inserted between the glass plates. The filter material will be placed and around the mould if the mould is the negative of the thickness profile, or it will be placed inside the mould if the mould is a hollow structure representing the thickness profile. The bulk of the material is made to solidify and the stack is left to rest to let air escape. The boundaries of the filter material are preferably not allowed to be completely solidified, i.e., the surface of the solidifying filter material may still be a little “wet” when it is separated from the mould. This effect may be obtained by the presence of softeners in the mould, which inhibit the complete curing of the filter resin at the contact interface. Preferably, a filter material with low adherence to glass is used. It is then possible in 210 to remove one of the glass plates and the mould without damaging any of them. The thickness of the filter material will then remain correct and provide the targeted transmission level. In 220 the second material is inserted and made to solidify and rest to let air escape. The glass plates may be used for moulding purposes only—their very smooth surface makes glass plates particularly suitable for this purpose—or one or both of them may be kept in place as part of the final product.

[0072] The following text will describe an example of one of the embodiments of the invention.

[0073] The desired brightness profile of two projectors of a multichannel projection display system was determined and the target was a filter with linear transmission profile. A mould was manufactured with a Polyjet OBJET Connex 3D printer, which prints 1600 dots per inch layers in the z-direction. The mould material was Tango Black Plus which has a rubber-like and dense structure. A dense structure is important so that the mould material creates a smooth interface with the filter material and so that the filter material does not penetrate the mould.

[0074] For filter material, TSE3032(A) rubber silicone, as sold by Momentive (from Columbus, Ohio, USA), was used. To increase the absorption of the filtering part, a tint was mixed with the rubber silicone. The tint was a carbon black paste from Sioen chemicals and the ratio between the tint and the rubber silicone resin was 10%/90%. The carbon black paste was thoroughly mixed with the rubber silicone resin. The solution was put inside a vacuum chamber to extract air that was introduced from the mixing process.

[0075] For the outer walls, glass plates with antireflection coatings were used. They were placed in a parallel arrangement and on top of each other with steel rods in between as spacers, and fixed together with clamps.

[0076] The tinted resin solution was introduced between the glass plates using a syringe and then left some time to rest for letting air escape. The glass plates with the filter material were then put in 50-60° C. for 3-4 hours to cure. It proved to be important that the bulk was solidified but that the outer boundaries of the material remained partly uncured.

[0077] One glass plate and the mould were removed without damaging the mould or the resin, and the second material (the non-tinted resin) was put in the cavity that had been formed by the mould. A (new) glass plate was placed again parallel and on top of the first glass plate and fixed with clamps. The glass unit with resins was again cured in 50-60° C. for 3-4 hours.

[0078] FIGS. 10 and 11 illustrate steps of two respective embodiments of the method according to the present invention. Without loss of generality, a square filter with a square zone of first material is illustrated. Due to the scale of the drawings, the non-linear interface has not been represented in faithful detail. The variations in shading are only intended to aid in discerning the individual represented parts, and are not intended to be indicative of the actual colour or degree of transparency of said parts. Where moulding cavities are shown, the skilled person will understand that further moulding elements may have to be added during the moulding steps to form an adequately delimited enclosure. In all embodiments of the method according to the present invention, the first material and the second material are different materials having substantially the same (real) refractive index, as described above. In the description of these steps, terms such as “top” and “bottom” refer to the orientation of elements as illustrated, without limiting the scope of the invention in any way to methods in which this particular orientation is respected. Details of the materials, their preparation, the selection and production of the moulds, etc., are not repeated here, but may applied as described in connection with other embodiments.

[0079] With reference to FIG. 10, an embodiment of the method for making an optical filter according to the present invention comprises the following steps. In this embodiment, a central part of the filter is moulded prior to a peripheral part.

[0080] In a first step 510, a first transmitting sheet 145 and a moulding element 99 are combined to form a first moulding cavity 120′. This moulding cavity 120′ is delimited on one side (in the illustrated case, the bottom of the cavity) by a part of a face of the first transmitting sheet 145 (in the illustrated case, the top of said sheet), and along an edge, in particular its peripheral edge, by a surface of the moulding element 99. This edge has a non-linear character, as described in more detail above.

[0081] In a second step 520, a first material 120 is inserted in the first moulding cavity 120′ in liquid state. At least the bulk of the first material 120 is then allowed to solidify. During this step, a sheet may optionally be applied to close off the top of the first moulding cavity 120′ and ensure a flat top surface—the second transmitting sheet 140 of the finished product (which is put in its final place in step 550 as described below) may optionally be used for this purpose.

[0082] In a third step 530, the moulding element 99 (and the optional top sheet, as the case may be) is removed or dissolved so as to produce a second moulding cavity 80′ in the space previously occupied by the moulding element 99. This second moulding cavity 80′ is indicated by vertical arrows pointing downwards. It shall be noted that, as this second moulding cavity 80′ consists of the empty space around the already moulded volume of first material 120, further (peripheral) moulding elements may be employed to adequately enclose this second cavity 80′ to allow the moulding to take place.

[0083] In a fourth step 540, a second material 80 is inserted in the second moulding cavity 80′ in liquid state.

[0084] In a fifth step 550, a second transmitting sheet 140 is placed on top of the first material 120 and the second material 80, parallel to the first transmitting sheet 145.

[0085] It shall be noted that step 540 and step 550 may be exchanged, in the sense that the second transmitting sheet 140 may be placed on top of the already moulded first material 120 as an additional delimiting element for the second moulding cavity 80′, in which case the entire material stack is complete upon completion of step 540.

[0086] With reference to FIG. 11, another embodiment of the method for making an optical filter according to the present invention comprises the following steps. In this embodiment, a peripheral part of the filter is moulded prior to a central part.

[0087] In a first step 510, a first transmitting sheet 145 and a moulding element 99 are combined to form a first moulding cavity 80′. This moulding cavity 80′ is delimited on one side (in the illustrated case, the bottom of the cavity) by a part of a face of the first transmitting sheet 145 (in the illustrated case, the top of said sheet), and along an edge (here, the “inner” edge of the central opening) by a surface of the moulding element 99. This edge has a non-linear character, as described in more detail above. This first moulding cavity 80′ is indicated by vertical arrows pointing downwards. It shall be noted that, as this first moulding cavity 80′ consists of the empty space around the moulding element 99, further moulding elements may be employed to adequately enclose this first cavity 80′ to allow the moulding to take place.

[0088] In a second step 520, a first material 80 is inserted in the first moulding cavity 80′ in liquid state. At least the bulk of the first material 80′ is then allowed to solidify.

[0089] In a third step 530, the moulding element 99 is removed so as to produce a second moulding cavity 120′ in the space previously occupied by the moulding element 99.

[0090] In a fourth step 540, a second material 120 is inserted in the second moulding cavity 120′ in liquid state.

[0091] In a fifth step 550, a second transmitting sheet 140 is placed on top of the first material 80 and the second material 120, parallel to the first transmitting sheet 145.

[0092] While the invention has been described hereinabove with reference to specific embodiments, this is done to illustrate and not to limit the invention, the scope of which is to be determined on the basis of the enclosed claims. Where certain features have only been described in the context of a filter embodiment or a method embodiment, these features can be used mutatis mutandis in embodiments of the other category to achieve the same technical effects and advantages.