Arbitrary surface optical element and method of making the same
An arbitrary surface optical element, such as a mirror for use in a rear projection television, includes a non-optical portion and an optical portion. The non-optical portion circumscribes the optical portion and has a thickness greater than the optical portion. Accordingly, the two portions cool at approximately the same rate, thereby minimizing warpage from differential cooling.
1. An optical element, comprising:
a part having a non-optical portion and a optical portion, the non-optical portion circumscribing edges of the optical portion and having a thermal mass greater than the optical portion such that the cooling rates of the non-optical and optical portions during joint manufacture are about equal to counteract edge effect experienced by the combined portions during the joint manufacture; and
a thin film layer on at least the optical portion, the thin film including one or more of a polarizing layer, a photochromic layer, a melanin layer, a mirror layer, a color filter, or an infrared filter.
2. The optical element of claim 1 , wherein the part is formed of a thermoplastic material and wherein the element further comprises a protective film between a metallic layer and the part.
3. The optical element of claim 2 , wherein the film is adhered to the part with a pressure sensitive or thermo set adhesive that has a higher melt temperature than either the film or a base material of the part.
4. The optical element of claim 1 , wherein the part is formed on a mold that forms a base of the optical element.
5. The optical element of claim 1 , wherein the non-optical portion includes at least one rib.
6. The optical element of claim 1 , wherein the non-optical portion extends outward from the optical portion with a dimension that is at least about twice the thickness of the optical portion.
7. The optical element of claim 1 , wherein the thin film is a polarizing layer.
8. The optical element of claim 1 , wherein the thin film is a photochromic layer.
9. The optical element of claim 1 , wherein the thin film is a melanin layer.
10. The optical element of claim 1 , wherein the thin film is a mirror layer.
11. The optical element of claim 1 , wherein the thin film is a color filter.
12. The optical element of claim 1 , wherein the thin film is an infrared filter.
13. A display, comprising:
a screen;
an optical engine that projects images; and
a first mirror positioned to reflect the images from the optical engine onto the screen, the mirror having a non-optical portion and an optical portion, the non-optical portion circumscribing edges of the optical portion and having a thermal mass greater than the optical portion such that the cooling rates of the non-optical and optical portions during joint manufacture are about equal to counteract edge effect experienced by the combined portions during the joint manufacture.
14. The display of claim 13 , wherein the optical portion includes a thin film layer disposed thereon.
15. The display of claim 14 , wherein the thin film includes one or more of a polarizing layer, a photochromic layer, a melanin layer, a mirror layer, a color filter, or an infrared filter.
16. The display of claim 13 , wherein the part is formed of a thermoplastic material and wherein the element further comprises a protective film between a-metallic layer and the part.
17. The display of claim 16 , wherein the film is adhered to the part with a pressure sensitive or thermo set adhesive that has a higher melt temperature than either the film or a base material of the part.
18. The display of claim 13 , wherein the part is formed on a mold that forms a base of the optical element.
19. The display of claim 13 , wherein the non-optical portion includes at least one rib.
20. The display of claim 13 , wherein the non-optical portion extends outward from the optical portion with a dimension that is at least about twice the thickness of the optical portion.
21. The display of claim 13 , further comprising a second mirror positioned to reflect the images from the light engine onto the first mirror.