A study of extended optimization of U-type rod for LED projectors

The paper proposes a new U-type integral rod for a miniature DLP projector's optical engine with a high-power LED source and L-type optics in order to minimize volumetric size of optical engine. In addition, Taguchi method is applied in this research in order to extendedly optimize the performance of optical engine after initial optimization by damped least square (DLS). A miniature optical engine with LED light source has the advantages of good power consumption, useable projected image, reasonable brightness and uniformity, compactness in volumetric size and decent performance specifically for high spatial frequencies. However, there are still rooms for development with regard to light efficiency and uniformity due to non-uniformity of LED light distribution. Two critical design methods are proposed in this research. Firstly, a "U-type integrator" working with high-power LED which not only causes rays to make a "U-turn" in order to minimize volumetric size of optical engine but also, after optimization, controls output uniformity well after extended optimization by Taguchi method. With regard to gain of optical efficiency, we also consider the factors of a U-type integrator: shape and length with a Taguchi optimizer. It is concluded that the newly developed design achieves good results for the performance and volumetric size of the module. Extended optimized parameter design is able to improve the luminous flux by 4.84%, the illumination uniformity 5.62% and the packing size by 12%.