Head-up display device
10365484 ยท 2019-07-30
Assignee
Inventors
- Kenji Ogiwara (Hachioji, JP)
- Kenji Hamada (Hachioji, JP)
- Shinobu Suga (Hachioji, JP)
- Yosuke Aoki (Machida, JP)
- Toshiya Takitani (Sakai, JP)
Cpc classification
G02B1/18
PHYSICS
B60K35/60
PERFORMING OPERATIONS; TRANSPORTING
B60K35/00
PERFORMING OPERATIONS; TRANSPORTING
International classification
B60K35/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A head-up display device includes: an image generator that emits light; and a display member including: a projection surface onto which the light is projected, wherein when the light is emitted to the projection surface, the light is reflected from the projection surface to display a real image passing through the display member and a virtual image; and a plate material including: a pair of optical surfaces, one positioned nearer to an observer side than the other, and either of which can serve as the projection surface; an end surface connecting peripheries of the pair of optical surfaces; and an end main surface formed at a predetermined a distance from the end surface to a reference line passing through a reference point and being orthogonal to a tangent plane at the reference point.
Claims
1. A head-up display device comprising: an image generator that emits light; and a display member comprising: a projection surface onto which the light is projected, wherein when the light is emitted to the projection surface, the light is reflected from the projection surface to display a real image passing through the display member and a virtual image; and a plate material comprising: a pair of optical surfaces, one positioned nearer to an observer side than the other, and either of which can serve as the projection surface; an end surface connecting peripheries of the pair of optical surfaces; and an end main surface formed at a predetermined distance from the end surface to a reference line passing through a reference point on the projection plane and being orthogonal to a tangent plane at the reference point, monotonically decreasing from the optical surface positioned nearer to the observing side to the other optical surface, in a cross-section of the display member taken along a virtual plane orthogonal to the tangent plane, passing through the reference point, and extending in a vertical direction, wherein the tangent plane is positioned at the reference point on a line passing through a midpoint of the projection surface and extending in a horizontal direction along the projection surface, the end main surface occupies at least 70% of the end surface in a thickness direction of the display member, and the following formula is satisfied in the cross-section:
e(arcsin(ndsin(nc))+arcsin(ndsin(2nc)))/2(1) wherein, e: an angle () between the reference line and an intended line of sight of an observer of the head-up display device, n: an angle () between a line normal to any point on the end main surface and the reference line, nd: a refractive index of the display member at a wavelength 555 nm, and c: critical angle ()=arcsin (1/nd).
2. The head-up display device according to claim 1, wherein when a tangent line is drawn at any point on the end main surface in the cross-section, an angle of the tangent line with respect to the reference line is not less than 10.
3. The head-up display device according to claim 2, wherein when the end main surface is approximated by an arc in the cross-section, the arc has a curvature radius of not more than 20 mm.
4. The head-up display device according to claim 2, wherein the end main surface is positioned at an upper end surface when the display member is installed.
5. The head-up display device according to claim 2, wherein the end surface comprises the end main surface and a chamfer in the cross-section.
6. The head-up display device according to claim 2, wherein the display member is made of resin, and hard coating is applied to the optical surface.
7. The head-up display device according to claim 2, wherein the optical surface positioned nearer to the observing side is a concave surface having a half-mirror function, and the other optical surface is a convex surface.
8. The head-up display device according to claim 2, wherein at least part of the end surface has an arithmetic average roughness of not less than 3 m.
9. The head-up display device according to claim 1, wherein the following formula is satisfied in the cross-section:
earcsin(ndsin(nc))(2).
10. The head-up display device according to claim 1, wherein when the end main surface is approximated by an arc in the cross-section, the arc has a curvature radius of not more than 20 mm.
11. The head-up display device according to claim 1, wherein the end main surface is positioned at an upper end surface when the display member is installed.
12. The head-up display device according to claim 1, wherein the display member is made of resin, and hard coating is applied to the optical surface.
13. The head-up display device according to claim 1, wherein at least part of the end surface has an arithmetic average roughness of not less than 3 m.
14. The head-up display device according to claim 1, wherein the head-up display device is mounted to an automobile and is installed at a position where the head-up display device can be observed by a driver of the automobile.
15. The head-up display device according to claim 14, wherein the head-up display device is installed on a dashboard of the automobile.
16. A head-up display device comprising: an image generator that emits light; and a display member comprising: a projection surface onto which the light is projected, wherein when the light is emitted to the projection surface, the light is reflected from the projection surface to display a real image passing through the display member and a virtual image; and a plate material comprising: a pair of optical surfaces, one positioned nearer to an observer side than the other, and either of which can serve as the projection surface; an end surface connecting peripheries of the pair of optical surfaces; and an end main surface formed at a predetermined distance from the end surface to a reference line passing through a reference point on the projection plane and being orthogonal to a tangent plane at the reference point, monotonically decreasing from the optical surface positioned nearer to the observing side to the other optical surface, in a cross-section of the display member taken along a virtual plane orthogonal to the tangent plane, passing through the reference point, and extending in a vertical direction, wherein the tangent plane is positioned at the reference point on a line passing through a midpoint of the projection surface and extending in a horizontal direction along the projection surface, the end main surface occupies at least 70% of the end surface in a thickness direction of the display member, and the end surface comprises the end main surface and a chamfer in the cross-section.
17. A head-up display device comprising: an image generator that emits light; and a display member comprising: a projection surface onto which the light is projected, wherein when the light is emitted to the projection surface, the light is reflected from the projection surface to display a real image passing through the display member and a virtual image; and a plate material comprising: a pair of optical surfaces, one positioned nearer to an observer side than the other, and either of which can serve as the projection surface; an end surface connecting peripheries of the pair of optical surfaces; and an end main surface formed at a predetermined distance from the end surface to a reference line passing through a reference point on the projection plane and being orthogonal to a tangent plane at the reference point, monotonically decreasing from the optical surface positioned nearer to the observing side to the other optical surface, in a cross-section of the display member taken along a virtual plane orthogonal to the tangent plane, passing through the reference point, and extending in a vertical direction, wherein the tangent plane is positioned at the reference point on a line passing through a midpoint of the projection surface and extending in a horizontal direction along the projection surface, the end main surface occupies at least 70% of the end surface in a thickness direction of the display member, and the optical surface positioned nearer to the observing side is a concave surface having a half-mirror function, and the other optical surface is a convex surface.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
(4)
(5)
(6)
DETAILED DESCRIPTION
(7) Hereinafter, embodiments will be described in detail with reference to the drawings.
(8)
(9) The liquid crystal display panel 111 is formed by applying polarizers on both of the front and back sides of a liquid crystal cell obtained by sealing a liquid crystal layer between a pair of translucent substrates on which transparent electrode films are formed. A light ray guided from a light source, not illustrated, in the image generation device 110 to a surface of the liquid crystal display panel 111 passes through the liquid crystal display panel 111 to be light L to be displayed, and the light L to be displayed is emitted to the concave mirror (or flat mirror) 120 constituting a projection optical system and is reflected to the combiner 200.
(10)
(11) The projection unit 201 can be made of a transparent resin, such as polycarbonate, cycloolefin polymer (COP), or acrylic, by using injection molding (using a pressure sensor in a mold). The projection unit 201 has a surface near the driver which is a projection surface (one optical surface) 201a for forming a virtual image. To form a virtual image, the projection surface 201a is a concave toric surface (may be an adjustable surface or spherical surface) having a curvature radius of not less than 100 mm, and the projection unit 201 has a back side (the other optical surface) 201c having a convex spherical surface or aspherical surface similar to the shape of the projection surface 201a. The projection unit 201 preferably has a constant thickness, but may be configured to have a thickness increasing or decreasing as separated from the center. In
(12) End surfaces of the projection unit 201 include an upper end surface 201b, side end surfaces 201e, and the like. Even if a conventional combiner is provided with an end surface roughened or finely textured, primary reflection or window reflection cannot be fully prevented only by providing the roughened or finely textured surface. Furthermore, in the combiner, although coating is often applied, for scratch prevention, to a surface to secure the hardness thereof, when the coating is applied to the surface which is roughened or finely textured, projections and recesses are buried upon coating, and light scattering effect may be lost. In contrast, masking of an end surface upon coating, or roughening or texturing of a surface in post processing is conceived, but the process is complicated and expensive. In contrast, as in one or more embodiments, when an end surface has a shape monotonically decreasing toward a back side, problems in the coating are eliminated and the cost is lowered. The shape of the upper end surface 201b will be described later. Each of the side end surface 201e may have a similar shape. The projection unit 201 may have a rounded chamfer at four corners. Note that the end surfaces may be a mirror surface.
(13) The projection surface 201a is a spherical surface or aspherical surface having a curvature radius of not less than 100 mm, preferably, less than 800 mm but not less than 200 mm, and a known half-mirror film is preferably deposited thereon so that the projection surface 201a has a half mirror function to have a transmittance of not less than 70% and not more than 80%. Furthermore, the combiner 200 preferably has a surface over which a hard coat is formed to prevent scratches or the like. Note that when the hard coat is applied to the combiner 200, the hard coat preferably has a refractive index substantially equal to that of the combiner 200 so that the hard coat can be considered as a part of the combiner 200 in the following formulas (1) to (2).
(14) The hard coat is applied by dip coating, spray coating, flow coating, spin coating, or the like. The hard coat is preferably applied to have a film thickness of 0.5 m to 20 m, preferably 1 m to 10 m. Then, on the projection surface 201a, a film containing SiO.sub.2, SiO, Al.sub.2O.sub.3, TiO.sub.2, or La.sub.2O.sub.2 is provided as an antireflection (AR) coat layer, and a film containing SiO.sub.2, SiO, Al.sub.2O.sub.3, TiO.sub.2, or La.sub.2O.sub.2 is provided as a half mirror layer. Note that, in the half mirror layer, a high refraction index layer and a low refraction index layer are alternately laminated. Furthermore, for securement of further preferable reflectance characteristics or from the viewpoint of securement of adhesion between the substrate and the hard coat, an intermediate refractive index layer may be appropriately inserted between some layers. Furthermore, ion-assisted processing, such as IAD, may be performed upon forming a hard coat layer. As a high refractive index material, an oxide or composite oxide including TiO.sub.2, La.sub.2O.sub.2, Ta.sub.2O.sub.5, ZrO.sub.2 or the like is preferably employed, as a low refractive index material, an oxide or composite oxide including SiO.sub.2, Al.sub.2O.sub.3, or the like is preferably employed, and as an intermediate refractive index material, which is to be inserted, an oxide or composite oxide including Al.sub.2O.sub.3, La.sub.2O.sub.2, or the like is preferably employed. In addition, for the antifoulant coat layer, a fluorine-based material is used to constitute a film formed by vacuum deposition. Note that the antifoulant coat layer may be formed by dip coating or the like. In film forming, for the half mirror, the hard coat, the half mirror coat, and antifoulant coat are preferably formed in this order from the substrate side, and for the AR coat, the hard coat, the AR coat, and the antifoulant coat are preferably formed in this order.
(15) The pair of mounted portions 202 extending to a lower end surface 201d of the projection unit 201 preferably has a rectangular extension surface having the same curvature radius as that of the projection surface 201a. Each of the mounted portions 202 is formed with two mounting holes 202a and 202b, and each of the two mounting holes 202a and 202b has an axis parallel to an optical axis. A bolt BT is inserted through any of the mounting holes 202a and 202b (see
(16)
(17) In
(18) Although in some countries the chamfered portions C1 and C2 need to be provided from the viewpoint of ensuring safety, the chamfered portions C1 and C2 may bring about primary reflected light, secondary reflected light, or window reflection due to the chamfered portions. In particular, window reflection may be intensified due to the chamfered portion C2 positioned near the observer. From the viewpoint of further reduction of the window reflection, the chamfered portion C2 is preferably has an arithmetic average roughness Ra of not less than 3 m to further prevent reflection (in particular, effective for window reflection in addition to primary reflection and secondary reflection). More preferably, not only the chamfered portion C2 but also an area of the end main surface 201q in the vicinity of the chamfered portion C2 (area occupying at least 10% of the end main surface) preferably has an arithmetic average roughness Ra of not less than 3 m. Although the curvature, if any, of the end main surface and the shape of the chamfered portion C2 are likely to increase window reflection, since the area of the end main surface 201q in the vicinity of the chamfered portion C2 (area occupying at least 10% of the end main surface) has an arithmetic average roughness Ra of not less than 3 m, light can be scattered, and the window reflection can be reduced. More preferably, the upper end surface 201b including the chamfered portion C1 and the end main surface 201q also has an arithmetic average roughness Ra of not less than 3 m. Note that each of the side end surfaces 201e also preferably has an arithmetic average roughness Ra of not less than 3 m. When the arithmetic average roughness Ra is not less than 3 m, sufficient light scattering effect can be obtained, but the arithmetic average roughness Ra may be not less than 3.5 m or not less than 4.0 m. Furthermore, the upper limit of general roughness is not particularly limited, but considering ease of processing a mold, the arithmetic average roughness Ra is preferably not more than 50 m. Here, the arithmetic average roughness Ra is measured using center line average roughness in accordance with JIS 0601-1976 (standards of arithmetic average roughness Ra). Note that when an end surface of the combiner 200 is not applied to coating or the like, the arithmetic average roughness of the end surface represents an arithmetic average roughness of the end surface itself, but when an end surface of the combiner 200 is applied to coating or the like, the arithmetic average roughness of the end surface represents an arithmetic average roughness of the end surface being coated. This is because even if an end surface of the combiner before coating has a roughness of not less than 3 m, the light scattering effect cannot be obtained from the projections and recesses buried due to coating. For roughening of an end surface, the end surface may be roughened in post processing after molding the combiner, but it is preferable to roughen a mold itself by using sandblasting, texturing, or the like in advance, and transfer the roughened shape of the mold to roughen the end surface, from the viewpoint of reduction of the process steps.
(19) In
(20) Here, when external light, such as sunlight, is incident on the end main surface 201q, the incident point on the end main surface 201q is defined as IP. An angle between a line EL connecting the center of the eye B of the driver DR with the incident point IP and a horizontal line is called a look down angle d. Furthermore, an installation angle (inclination angle) of the combiner 200 is defined as t (here, a crossing angle between the horizontal line HL and the reference line SL in
(21) At that time, when an external light beam LB, such as sunlight, is incident at the incident point IP on the end main surface 201q, the external light beam LB is partially reflected, but the rest of the external light beam LB enters the combiner 200 and guided in the combiner 200 while being totally internally reflected. According to one or more embodiments, in
(22) Furthermore, in
(23) In contrast, according to the work of the present inventors, it was found that light entering the combiner 200 from the upper end surface and guided therein is returned to the end main surface 201q and reflected from the end main surface 201q to be emitted from the projection surface 201a, but when such light enters the eye B of the driver DR, the light bothers the driver DR. This is called secondary reflection. Therefore, in one or more embodiments, the following measures are taken.
(24) In the following, an example of an optical path causing the secondary reflection will be described. Note that an example of the upper end surface is described here, but the same is applied to the side end surfaces.
e(U+L)/2=(arcsin(ndsin(nc))+arcsin(ndsin(2nc)))/2(1)
(25) wherein, n: an angle () between the line NL normal to the destination OP of the end main surface 201q and the reference line SL, nd: a refractive index of the combiner 200 at a wavelength of 555 nm, and c: a critical angle ()=arcsin (1/nd)
(26) In order to reliably prevent the secondary reflected light, the following formula is preferably satisfied in particular.
earcsin(ndsin(nc))(2)
(27) From the viewpoint of the reduction of reflected light based on internal reflection, formulas (1) to (2) are preferably satisfied in the whole area of at least one end surface, but from the viewpoint of reliable moldability of the combiner 200 and reliable safety for preventing the sharpness of a corner, margins for the chamfered portions C1 and C2 are preferably provided and formulas (1) to (2) are preferably satisfied in the whole end main surface 201q other than the chamfered portions C1 and C2. Further preferably, formulas (1) to (2) are preferably satisfied also in the region of the chamfered portions C1 and C2 as much as possible. Note that a commercially available combiner is sampled and cut to obtain a cross-section thereof as illustrated in
(28) In
(29) Hereinafter, combiner evaluation performed by the present inventors will be described. The present inventors confirmed the effect of reducing secondary reflection by changing the shape of the upper end surface 201b on the basis of the cross-section of
(30) TABLE-US-00001 TABLE 1 Intensity of secondary reflected light (60% range is 100%) L U e 60% 100% 68.3 14.6 41.45 65% 92% 75% 80% 85% 71%
(31) TABLE-US-00002 TABLE 2 Effect of reducing Range secondary reflected light less than 70% (fair) not less than 70%- (good) less than 80% not less than 80% (excellent)
(32) Next, the present inventors performed simulation by using a combiner having a flat end main surface 201q as a model with reference to
(33) (Combiner Specification)
(34) End main surface 201q: flat surface
(35) Inclination angle a of the tangent line CLI to the end main surface 201q with respect to the reference line SL: [0], [13], and [16]
(36) Thickness of the combiner: 3 mm
(37) Radius of the chamfered portion C1: 0.15 mm
(38) Radius of the chamfered portion C2: 0.3 mm
(39) Refractive index nd of the combiner: 1.585
(40) Installation angle t of the combiner: 10
(41) Look down angle d: 5
(42) View angle e: 15
(43) (U+L)/2: 41.45 (<e)
(44) TABLE-US-00003 TABLE 3 Tangent angle a Intensity of primary reflected light to reference line [] (a = 0 is 100%) 0 100% 13 90% 16 30%
(45) TABLE-US-00004 TABLE 4 Tangent angle a Effect of reducing to reference line [] primary reflected light 0-10 (fair) 10-15 (good) not less than 15 (excellent)
(46) Next, the present inventors performed simulation by using a combiner having a curved end main surface 201q as a model with reference to
(47) (Combiner Specification)
(48) Curvature radius R of the end main surface 201q: [5.5 mm], [12 mm], and [25 mm]
(49) Thickness of the combiner: 3 mm
(50) Radius of the chamfered portion C1: 0.15 mm
(51) Radius of the chamfered portion C2: 0.3 mm
(52) Refractive index nd of the combiner: 1.585
(53) Installation angle t of the combiner: 10
(54) Look down angle d: 5
(55) View angle e: 15
(56) TABLE-US-00005 TABLE 5 R Intensity of light reflected to windshield [mm] (R = is 100%) 5.5 79% 12 98% 25 99%
(57) TABLE-US-00006 TABLE 6 R Effect of reducing light [mm] reflected to windshield 10 (excellent) 10-20 (good) not less than 20 (fair)
(58) Furthermore, the present inventors actually formed, by injection molding, combiners having the following specifications, one of which is formed by a mold roughened by texturing to have an upper end surface 201b having an arithmetic average roughness of 3.5 m as a whole, and another one of which is formed by a mold not textured (an arithmetic average roughness of the whole upper end surface 201b after molding of 0.1 m: no roughened shape), and combiners having an end main surface 201q having a curvature radius of (flat surface substantially parallel to a horizontal direction). As illustrated in
(59) (Combiner Specification)
(60) Curvature radius R of the end main surface 201q: [5.5 mm]
(61) Thickness of the combiner: 3 mm
(62) Radius of the chamfered portion C1: 0.15 mm
(63) Radius of the chamfered portion C2: 0.3 mm
(64) Refractive index nd of the combiner: 1.585
(65) Installation angle t of combiner: 5
(66) Look down angle d: 8
(67) View angle e: 13
(68) Material: polycarbonate
(69) TABLE-US-00007 TABLE 7 Curvature radius R of Intensity of light reflected from end main surface windshield (R = without [mm] Roughened shape roughened shape is 100%) without (arithmetic mean roughness 0.1 m) 100% with (arithmetic mean roughness 3.5 m) 52.4% 5.5 without (arithmetic mean roughness 0.1 m) 57.1% 5.5 with (arithmetic mean roughness 3.5 m) 19.0%
(70) It is clear for a person skilled in the art from the embodiments, examples, or technical concepts described in the present specification that the present invention should not be limited to the embodiments and examples described in the present specification, and includes other embodiments, examples, and modifications. For example, the head-up display device according to the present invention can be used for, for example, an airplane or a heavy machine, in addition to an automobile.
REFERENCE SIGNS LIST
(71) 100 IMAGE GENERATION UNIT 110 IMAGE GENERATION DEVICE 111 LIQUID CRYSTAL DISPLAY PANEL 120 CONCAVE MIRROR 130 HOUSING 200 COMBINER (DISPLAY MEMBER) 201 PROJECTION UNIT 201a PROJECTION SURFACE (OPTICAL SURFACE) 201b UPPER END SURFACE 201c BACK SIDE (OPTICAL SURFACE) 201d LOWER END SURFACE 201e SIDE END SURFACE 201q END MAIN SURFACE C1, C2 CHAMFERED PORTION DB DASHBOARD DR DRIVER (OBSERVER) SL REFERENCE LINE VH VEHICLE WS WINDSHIELD
(72) Although the disclosure has been described with respect to only a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that various other embodiments may be devised without departing from the scope of the present invention. Accordingly, the scope of the invention should be limited only by the attached claims.