JP2003270717A - Optical device manufacturing apparatus and optical device manufacturing method - Google Patents

Abstract

(57) [Problem] To provide an optical device that can smoothly adjust the position of a light modulation device even when a head body shape is complicated in response to high brightness and high performance of a projector. A manufacturing apparatus and a method for manufacturing an optical device are provided. An apparatus for manufacturing an optical device includes a six-axis position adjustment unit that adjusts a position of a light modulation device;
A support jig 33 for mounting and fixing the optical device 140 and a light beam detection device 40 are provided. The support jig 33 has a support piece 336 for supporting the weight of the panel unit 190 (light modulation device 141). I have. Here, when the optical device 140 is installed on the support jig 33, the support piece 336 faces the opening 151 </ b> C formed in the head body 150 and moves up and down through the opening 151 </ b> C.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a plurality of light modulators for modulating a plurality of color lights for each color light according to image information.
In order to manufacture an optical device including a color synthesizing optical device that synthesizes the light fluxes modulated by the respective light modulators, the mutual positions of the respective light modulators are adjusted, and the light flux incident end surface of the color synthesizing optical device is adjusted. The present invention relates to an optical device manufacturing apparatus and an optical device manufacturing method for fixing each optical modulator.

[0002]

2. Description of the Related Art Conventionally, a light beam emitted from a light source is separated by a dichroic mirror into red, green, and blue color lights of three primary colors, and three liquid crystal panels are used to modulate each color light according to image information, and an image is displayed. A so-called three-plate type projector is known in which the modulated color lights are combined by a cross dichroic prism and a color image is enlarged and projected through a projection lens. In such a projector, each liquid crystal panel must be located at the back focus position of the projection lens, and one display pixel is displayed by the additive color mixture of the three primary colors of red, green, and blue. In order to obtain a clear image, it is necessary to prevent the pixel shift between the liquid crystal panels and the distance shift from the projection lens.
At the time of manufacturing a projector, focus adjustment for accurately arranging each liquid crystal panel at the back focus position of the projection lens and alignment adjustment for matching pixels of each liquid crystal panel must be performed with high accuracy. Therefore, in an optical device including a liquid crystal panel and a cross dichroic prism, in order to position the liquid crystal panel with respect to the projection lens with high accuracy, the cross dichroic prism and the liquid crystal panel are integrated with the projection lens. It has a structure to turn it into a solid.

Usually, when manufacturing an optical device as described above, a cross dichroic prism is placed and fixed on a structure, and a liquid crystal panel is gripped by using a position adjusting section constituting the manufacturing device, and then position adjustment is performed. The liquid crystal panel is mounted on the light-incident end surface of the cross dichroic prism via a thermosetting adhesive or a photocurable adhesive. Then, the position adjusting unit adjusts the position of the liquid crystal panel with respect to the light flux incident end surface of the cross dichroic prism, and cures the adhesive to manufacture the optical device.

[0004]

In recent years, the structure has a polarizing plate on the light beam incident side in order to maximize the cooling performance around the liquid crystal panel in order to cope with the high brightness of the projector. The holding member and the like are integrally formed.
However, in the optical device manufacturing apparatus as described above,
After the liquid crystal panel is gripped by using the position adjusting unit, the position adjusting unit is moved to mount the liquid crystal panel on the light flux incident end surface of the cross dichroic prism. Because of the shape, the liquid crystal panel collides with the structure and the liquid crystal panel cannot be mounted on the light flux incident end surface of the cross dichroic prism.

Here, after the liquid crystal panel is mounted on the cross dichroic prism via a thermosetting adhesive or a photocurable adhesive, the position adjusting portion is moved in a state where the adhesive is not cured to move the liquid crystal panel. It is possible to manufacture the optical device by gripping the end face of the device with the position adjusting unit, adjusting the position of each light modulator, and curing the adhesive, but as described above, with the increase in brightness of the projector. When the holding frame that holds the liquid crystal panel is made of metal for the purpose of improving the cooling performance, the weight of the periphery of the liquid crystal panel is increasing. The weight of the panel cannot be secured, the mounting state of the liquid crystal panel on the cross dichroic prism is destroyed, and the liquid crystal panel falls before the position adjustment is performed by the position adjustment unit. To not be manufactured, there is a problem in that.

An object of the present invention is to provide a high brightness
To provide an optical device manufacturing apparatus and an optical device manufacturing method capable of smoothly adjusting the position of a light modulation device even when the shape of a structure becomes complicated in response to higher performance. is there.

[0007]

SUMMARY OF THE INVENTION An optical device manufacturing apparatus according to the present invention comprises a plurality of light modulators for modulating a plurality of color lights for each color light according to image information, and light fluxes modulated by the respective light modulators. In order to manufacture an optical device including a color synthesizing optical device for synthesizing a color synthesizing device, an optical device for adjusting the mutual positions of the respective light modulating devices and fixing each light modulating device to a light flux incident end face of the color synthesizing optical device. A mounting table on which the color synthesizing optical device is placed, a position of each light modulator with respect to the color synthesizing optical device, and a position adjusting unit that adjusts the position of each light modulator. After adjusting the mutual positions of the respective light modulators, a positioning fixing portion for positioning and fixing the light modulators is provided on the light flux incident end surface, and the mounting table supports the light modulators from the lower side in the vertical direction. A support piece is provided, the support piece And it is characterized in that it is capable project and retreat relative to the mounting surface of the mounting table.

According to the present invention as described above, the optical device manufacturing apparatus includes the mounting table, the position adjusting section, and the positioning fixing section, and the supporting table is provided on the mounting table. When the optical modulator is attached to the optical device using a thermosetting adhesive or a photocurable adhesive, even if the self-weight of the optical modulator cannot be held only by the surface tension of the adhesive, The self-weight of the light modulator can be supported by the support piece, and the mounting state of the light modulator to the color combining optical device can be maintained. Therefore,
When manufacturing an optical device, position adjustment is performed by the position adjustment unit from the state in which the light modulation device is mounted on the color synthesis optical device, and the light modulation device is positioned on the light flux incident end surface of the color synthesis optical device by the positioning fixing unit. Because it can be fixed,
Even if the structure has a complicated shape, the optical device can be manufactured.

Further, since the support piece is capable of projecting and retracting with respect to the mounting surface of the mounting table, the support piece allows
The optical modulator is supported to secure the mounting state of the optical modulator to the color synthesizing optical device, and from the mounted state, the position adjusting unit adjusts the position of the optical modulator with respect to the light flux incident end surface of the color synthesizing optical device. When performing, the position of the optical modulator can be smoothly adjusted by the position adjusting unit by moving the support piece to a position where it does not interfere with the optical modulator.

In the optical device manufacturing apparatus of the present invention, the optical device includes the color synthesizing optical device and a structure to which a projection optical system for enlarging and projecting a light flux emitted from the color synthesizing optical device is attached. An opening for cooling the light modulator is formed in the structure, and the support piece is
It is preferably arranged at a position corresponding to this opening.
In such a configuration, the optical device includes a structure, an opening is formed in the structure, and the support piece is arranged at a position corresponding to the opening, so that the opening passes through the opening.
It is possible to cause the support piece to project and retract.

In the optical device manufacturing apparatus of the present invention, it is preferable that the support piece is provided with an outer shape position reference surface for positioning the light modulator with the outer shape reference. In such a configuration, since the support piece is provided with the outer shape reference surface, the optical modulator can be installed at an optimum position with respect to the support piece. Further, if this outer position reference plane is set at a predetermined design position with respect to the light beam incident end surface of the color synthesizing optical device, the light beam incident end surface of the color synthesizing optical device is supported by the supporting piece of the light modulator. It is possible to set the initial position of the light modulator with respect to. Therefore, when the light modulator is mounted on the color synthesizing optical device, the outer shape of the light modulator is positioned,
It is possible to omit the rough adjustment of the light modulation device for the light flux incident end surface of the color combining optical device, which is performed by the position adjusting unit, and it is possible to reduce the cycle time in manufacturing the optical device.

In the optical device manufacturing apparatus of the present invention, the position adjusting section includes an adsorption section for adsorbing and holding the optical modulation apparatus, and an adsorption state for detecting an adsorption state of the optical modulation apparatus by the adsorption section. It is preferable to include a detection means and a support piece control means for controlling the movement of the support piece in accordance with the detected suction state. In such a configuration, since the position adjusting section includes the suction section, even if the outer shape of the light modulation apparatus becomes complicated, the suction section sucks the end surface of the light modulation apparatus. Thus, the light modulator can be held, and the structure for holding the light modulator in the position adjusting unit can be simplified.

Further, since the optical device manufacturing apparatus is provided with the suction state detecting means, the suction state detecting means senses the suction state of the light modulation device by the suction portion, and the holding state of the light modulation device is accurately determined. Can be grasped. Therefore, when the suction state by the suction unit is lowered, it can be detected by the suction state detection means, and the holding state of the optical modulation device cannot be secured due to the reduction of the suction state, and the light modulation device falls from the suction unit. However, it is possible to prevent the optical modulator from being damaged.

Further, since the optical device manufacturing apparatus is provided with the support piece control means, the support piece is moved and controlled in accordance with the suction state detected by the suction state detection means,
The support piece and the light modulation device can be separated from each other. Therefore, the suction piece is set to a stable suction state, and when the suction state detected by the suction state detection means is equal to or more than the set suction state, the support piece movement control means controls the support piece. By doing so, the support piece can be moved while the holding state of the optical modulator by the suction portion is stably ensured.

In the optical device manufacturing apparatus of the present invention, the light modulation device is positioned and fixed to the light flux incident end surface of the color combining optical device by a photo-curing adhesive, and the positioning and fixing portion is formed by the photo-curing device. It is preferable to include a light beam irradiation unit for curing the mold adhesive. In such a configuration,
Since the positioning and fixing part is equipped with a light beam irradiation part, position adjustment of the light modulation device with respect to the light flux incident end face of the color synthesizing optical device is performed in an uncured state by applying a photo-curable adhesive, and position adjustment is completed. After that, the photocurable adhesive can be cured by the light beam irradiation section, so that the optical device can be efficiently manufactured.

In the optical device manufacturing apparatus of the present invention, the light modulator includes a light modulator main body for performing light modulation, and a substantially rectangular holding frame for housing and holding the light modulator main body.
It is preferable that holes are formed in the four corners of the holding frame, and the plurality of light beam irradiation units are provided in accordance with the hole positions of the four corners of the holding frame. In such a configuration, the light modulation device includes the light modulation element body and the holding frame having holes at the four corners, and the plurality of light beam irradiation units are provided according to the hole positions at the four corners of the holding frame. After adjusting the position of the light modulation device, a light beam can be emitted from the light beam irradiation portion through the hole of the holding frame, and the light modulation device and the color synthesizing optical device can be fixed by adhesion.

In the apparatus for manufacturing an optical device of the present invention, a fixed frame fixed by a photo-curing adhesive is provided on the light-incident end surface of the color combining optical device, and the optical modulator includes this fixed frame. It is preferable that a plurality of the light beam irradiating portions are fixed to the light flux incident end face via the light beam incident end face of the color synthesizing optical device according to the joint position between the light flux incident end face and the fixed frame. Usually, between the light modulator and the color synthesizing optical device, a polarizing plate that transmits only the light flux having a predetermined polarization axis among the light flux emitted from the light modulator is interposed.
In order to improve the cooling efficiency of the light modulator and the polarizing plate in response to the increase in the brightness of the projector, when the structure in which the polarizing plate is held by the metal fixing frame is adopted, The light flux from the light flux incident side is blocked by the fixed frame, and it becomes difficult to integrally form the light modulation device, the fixed frame, and the color synthesizing optical device by using a photocurable adhesive. Here, a plurality of light beam irradiation units are provided in accordance with the position of the joint between the light flux incident end surface of the color synthesizing optical device and the fixed frame, so that the light beam is irradiated between the color synthesizing optical device and the fixed frame. Even when adopting a structure in which the above polarizing plate is held by a metal fixing frame,
The light modulation device, the fixing frame, and the color synthesizing optical device can be integrally formed by using a photocurable adhesive.

The method of manufacturing an optical device according to the present invention comprises a plurality of light modulators for modulating a plurality of color lights for each color light according to image information, and color combining optics for combining the light fluxes modulated by the respective light modulators. A method of manufacturing an optical device, comprising adjusting the mutual positions of the respective light modulators and fixing the respective light modulators to the light flux incident end surface of the color combining optical device in order to manufacture an optical device including the device. An adhesive applying step of applying a photo-curable adhesive to the light modulating device, and a light flux incident end surface of the color synthesizing optical device while supporting the light modulating device coated with the photo-curable adhesive with a support piece. A light modulator arranging step of arranging the light modulator by closely adhering a photo-curable adhesive to, and a suction holding step of sucking and holding an image forming area of the light modulator,
A support release step of releasing the support of the light modulator by the support piece on condition that the light is adsorbed and held, and a position for performing position adjustment of the adsorbed and held light modulator with respect to the light flux incident end face. It is preferable to include an adjusting step and a positioning step of irradiating the light-curable adhesive with a light beam in a state where the adjusted position of the light modulation device is held to position and fix the light modulation device. .

According to the present invention as described above, the method for manufacturing an optical device includes an adhesive applying step, an optical modulator arranging step, a suction holding step, a support releasing step, a position adjusting step, and a positioning step. By applying a photocurable adhesive to the light modulator, and while supporting the light modulator with a support piece, the light modulator is arranged by closely adhering the light curable adhesive to the light flux incident end surface of the color combining optical device. Then, it is possible to shift to the next step (adsorption holding step, support releasing step, position adjusting step, and positioning step) while ensuring the holding state of the optical modulator. Therefore, even if the shape of the structure is complicated or the weight of the light modulation device is increased as the cooling performance of the projector is improved, the manufacturing of the optical device can be smoothly performed. Also, in the adsorption holding step,
By forming a support release step of adsorbing and holding the image forming area of the light modulating device and releasing the support of the light modulating device by the support piece on condition that the adhering and holding is performed, the image forming of the light modulating device is performed. It is possible to move to the next step (position adjusting step and positioning step) in a state in which the suction and holding of the region is reliably performed.

[0020]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the drawings. [1. Structure of Projector] FIG. 1 is a diagram showing a structure of a projector 100 including an optical device including a plurality of light modulation devices and a color combining optical device according to an embodiment of the present invention. The projector 100 includes an integrator illumination optical system 110, a color separation optical system 120, and a relay optical system 130.
And an optical device 140 and a projection lens 160.
These optical components are mounted and fixed in a light guide as a housing for optical components.

The integrator illumination optical system 110 includes three liquid crystal panels 141R and 14R constituting the optical device 140.
1G, 141B (shown as liquid crystal panels 141R, 141G, 141B respectively for red, green, and blue color lights) is an optical system for illuminating the image forming areas substantially uniformly, and includes a light source device 111 and a first lens array. 112, the second lens array 113, the polarization conversion element 114, and the superimposing lens 11
5 and.

Of these, the light source device 111 includes a light source lamp 111A for emitting a radial ray and an ellipsoidal mirror 1 for reflecting the emitted light emitted from the light source lamp 111A.
11B and the ellipsoidal mirror 1 emitted from the light source lamp 111A.
And a collimating concave lens 111C that collimates the light reflected by 11B. The parallelizing concave lens 111C
A UV filter (not shown) is provided on the plane portion of. Further, as the light source lamp 111A, a halogen lamp, a metal halide lamp, or a high pressure mercury lamp is often used. Further, a parabolic mirror may be used instead of the ellipsoidal mirror 111B and the collimating concave lens 111C.

Further, the first lens array 112, the second lens array 113, and the polarization conversion element 114 are integrally combined and installed and fixed in the housing. The first lens array 112 has a configuration in which small lenses having a substantially rectangular outline when viewed in the optical axis direction are arranged in a matrix. Each small lens splits the light flux emitted from the light source lamp 111A into a plurality of partial light fluxes. The outline shape of each small lens is the liquid crystal panel 141R, 141G, 14
It is set so as to be substantially similar to the shape of the image forming area of 1B. For example, the liquid crystal panels 141R and 141
If the aspect ratio (ratio of horizontal and vertical dimensions) of the G and 141B image forming regions is 4: 3, the aspect ratio of each small lens is also set to 4: 3.

The second lens array 113 has substantially the same structure as the first lens array 112, and has a structure in which small lenses are arranged in a matrix. The second lens array 112, together with the superimposing lens 115, includes a first lens array 112.
The image of each small lens of the lens array 112 is displayed on the liquid crystal panel 14.
It has a function of forming an image on 1R, 141G and 141B.

The polarization conversion element 114 is arranged between the second lens array 113 and the superimposing lens 115, and is unitized with the second lens array 113. The polarization conversion element 114 as described above converts the light from the second lens array 113 into one type of polarized light, which improves the light utilization efficiency of the optical device 140.

Specifically, the polarization conversion element 114 is set to 1
Each of the partial lights converted into the polarized light of the type is a superimposing lens 11
5 finally the liquid crystal panel 141 of the optical device 140
Substantially superimposed on R, 141G, 141B. In a projector using a liquid crystal panel of a type that modulates polarized light, only one kind of polarized light can be used, and therefore almost half of the light from the light source lamp 111A that emits randomly polarized light cannot be used. Therefore, the polarization conversion element 11
4, the light emitted from the light source lamp 111A is converted into almost one type of polarized light, and the light utilization efficiency of the optical device 140 is improved. Such a polarization conversion element 114 is introduced, for example, in Japanese Patent Laid-Open No. 8-304739.

The color separation optical system 120 is provided with two dichroic mirrors 121 and 122 and a reflection mirror 123, and a plurality of partial light beams emitted from the integrator illumination optical system 110 by the dichroic mirrors 121 and 122 are red and green. , And has a function of separating into three color lights of blue.

The relay optical system 130 includes the incident side lens 13
1, a relay lens 133, and a reflection mirror 132, 1
34, and has a function of guiding the colored light and the red light separated by the color separation optical system 120 to the liquid crystal panel 141R.

At this time, in the dichroic mirror 121 of the color separation optical system 120, the integrator illumination optical system 11 is used.
The blue light component of the light flux emitted from 0 is reflected, and the red light component and the green light component are transmitted. The blue light reflected by the dichroic mirror 121 is reflected by the reflection mirror 123, passes through the field lens 170, and reaches the blue liquid crystal panel 141B. The field lens 170 converts each partial light flux emitted from the second lens array 113 into a light flux parallel to the central axis (chief ray) thereof. The same applies to the field lens 170 provided on the light incident side of the other liquid crystal panels 141G and 141R.

Of the red light and the green light transmitted through the dichroic mirror 121, the green light is reflected by the dichroic mirror 122, passes through the field lens 170, and reaches the liquid crystal panel 141G for green. On the other hand, the red light passes through the dichroic mirror 122, passes through the relay optical system 130, further passes through the field lens 170, and reaches the liquid crystal panel 141R for red light. The relay optical system 130 is used for the red light because the length of the optical path of the red light is longer than the optical paths of the other color lights, so that the reduction of the light use efficiency due to the divergence of the light or the like is prevented. This is because. That is, the partial light flux incident on the incident side lens 131 is directly transmitted to the field lens 170.

The optical device 140 modulates the light flux emitted from the light source lamp 111A in accordance with image information, synthesizes the modulated light flux, and emits the light flux. The liquid crystal panel 141R serves as three light modulation devices. , 141G, 141B,
A cross dichroic prism 144 as a color combining optical device is provided. Liquid crystal panels 141R, 141
G and 141B are, for example, those in which a polysilicon TFT is used as a switching element, and the color separation optical system 12
Each color light separated by 0 is emitted from these three liquid crystal panels 14
1R, 141G, 141B, an incident side polarization plate 142 on the light flux incidence side, and an emission side polarization plate 1 on the emission side.
By 43, it is modulated according to image information to form an optical image. Although not specifically shown, the liquid crystal panel 141
R, 141G, and 141B are a driving substrate provided with pixel electrodes in which TFT switching elements are arranged in a matrix and a voltage is applied by the switching elements, and a counter substrate provided with counter electrodes corresponding to the pixel electrodes. Composed of.

The cross dichroic prism 144 is
The image modulated for each color light emitted from the three liquid crystal panels 141R, 141G, and 141B is combined to form a color image. In the cross dichroic prism 144, a dielectric multilayer film that reflects red light and a dielectric multilayer film that reflects blue light are formed in a substantially X shape along the interfaces of the four rectangular prisms. Three color lights are combined by the dielectric multilayer film. Then, the color image combined by the cross dichroic prism 144 is emitted from the projection lens 160 and enlarged and projected on the screen.

The projection lens 160 is for enlarging and projecting the optical image modulated by the optical device 140, and although not specifically shown, a magnification conversion lens group of the zoom lens and a focus adjustment lens group, etc. By changing the mutual position of these lens groups, magnification conversion and focus adjustment of the projected image are performed. This projection lens 160
Is provided with a metal lens barrel in order to ensure strength against external force.

[2. Structure of Optical Device] FIG. 2 is an exploded perspective view showing an assembly structure of the optical device 140 and the projection lens 160. The optical device 140 includes liquid crystal panels 141R and 1R.
Optical device main body 140A having 41G and 141B and cross dichroic prism 144, and head body 15 as a structure for supporting and fixing the optical device main body 140A.
It is configured with 0 and. As shown in FIG. 2, the optical device 140 and the projection lens 160 are integrally combined by the projection lens installation portion 153 of the head body 150, which will be described later, and by thus integrating, the high performance of the projector 100 is achieved. The projection lens 160 is positioned with high precision with respect to the optical device main body 140A.

[2-1. Structure of Optical Device Main Body] FIG.
FIG. 3 is an exploded perspective view showing the structure of an optical device body 140A.
The optical device body 140A includes liquid crystal panels 141R and 141R.
The G and 141B and the cross dichroic prism 144 are integrally formed, and an optical modulator 141 for performing optical modulation and a cross dichroic prism 144.
And a pedestal 145 fixed to the lower surface of the cross dichroic prism 144, and a holding member 147 as a fixed frame interposed between the light modulator 141 and the cross dichroic prism 144. In FIG. 3, in order to simplify the drawing, the optical modulator 14
The figure which decomposed | disassembled only the red light incident side of 1 is shown. In the following description, the red light incident side is also described, but the green and blue light incident sides are the same.

The light modulator 141 comprises a liquid crystal panel 141R as a light modulator and a holding frame 146 for holding and holding the liquid crystal panel 141R. The liquid crystal panel 141R includes a drive substrate (for example, a TFT substrate) 141.
Liquid crystal is sealed between C and a glass substrate which is the counter substrate 141D thereof, and a control cable 141E extends from between these glass substrates. In addition, the drive substrate 141C and / or the counter substrate 141D is usually
The position of the panel surface of the liquid crystal panel 141R is shifted from the back focus position of the projection lens 160, and a light-transmissive dustproof plate is attached to make the dust optically adhering to the panel surface inconspicuous. As the heat-resistant dustproof plate, a plate body having good thermal conductivity such as sapphire or quartz is fixed.

The holding frame 146 includes a container 146A for accommodating the liquid crystal panel 141R, and a support plate 146B for engaging with the container 146A and pressingly fixing the liquid crystal panel 141R.
Consists of. The holding frame 146 is used for each liquid crystal panel 14
It is assumed that the liquid crystal panel 141R is stored by gripping the outer periphery of the light-transmitting dustproof plate fixed to the counter substrate 141D of 1R, and the opening 146C is provided at a position corresponding to the panel surface of the stored liquid crystal panel 141R. Further, holes 146D are formed in the four corners.

The housing 146A and the support plate 146B are fixed by the hooks 1 provided on both the left and right sides of the support plate 146B.
46B1 and the hook engaging portion 146A1 provided at the corresponding position of the container 146A. Here, the liquid crystal panel 141R is exposed at the opening 146C of the holding frame 146, and this portion becomes an image forming area. That is, R color light is introduced into this portion of the liquid crystal panel 141R, and an optical image is formed according to image information. Further, a light-shielding film (not shown) is provided on the end face of the support plate 146B on the light beam exit side, and the cross dichroic prism 144 is provided.
Cross dichroic prism 1
Further, the reflection to the 44 side is prevented, and the deterioration of the contrast due to stray light is prevented.

The pedestal 145 is fixed to the lower surface of the cross dichroic prism 144, is a substantially rectangular plate-like body, and has an outer peripheral shape of the cross dichroic prism 14.
It is slightly smaller than No. 4, and the side surface is located inside the side surface of the cross dichroic prism 144. In addition, mounting portions 145A for fixing the optical device body 140A to the head body 150 are formed at four corners of the pedestal 145, and the optical device body 140A is mounted on the lower surface of the pedestal 145. Positioning pins 145B for positioning on the body 150 are formed.

The holding member 147 is used for each liquid crystal panel 141.
The holding frame 146 that accommodates R, 141G, and 141B is held and fixed, and the exit-side polarization plate 143 is fixed. The rectangular plate 147A and the rectangular plate 147 are fixed.
A pin 147A1 protruding from the four corners of A is provided. The holding member 147 is interposed between the cross dichroic prism 144 and the holding frame 146, and the end surface of the holding member 147 opposite to the pin 147A1 is adhesively fixed to the side surface of the cross dichroic prism 144. Hole 146 of pin 147A1 and holding frame 146
The holding member 147 and the holding frame 146 are adhesively fixed to each other via D.

The rectangular plate member 147A has a rectangular opening 147A2 formed substantially at the center thereof, and a recess 147A4 formed along the upper and lower edges thereof. This opening 1
47A2 corresponds to the image forming area of the liquid crystal panel 141R when the liquid crystal panel 141R is mounted. In addition, a light shielding film (not shown) is provided on the end surface of the rectangular plate-shaped body 147A on the light exit side, as with the holding frame 146. An engagement groove 147A3 is formed so as to surround the opening 147A2, and a polarization film is attached on the sapphire substrate using a transparent adhesive so as to engage with the engagement groove 147A3. The plate 143 is fixed by double-sided tape or adhesive.

The pin 147A1 is formed in a substantially conical shape that tapers from the base end to the tip, and the holding member 14 is formed.
When an ultraviolet curable adhesive is used to fix 7 and the holding frame 146, the reflected light flux at the tip of the pin 147A1 is reduced when the ultraviolet ray is irradiated from the tip of the pin 147A1 to cure, and the pin 147A1 and The joining portion (ultraviolet adhesive) with the holding frame 146 has a structure in which ultraviolet rays are sufficiently transmitted, so that the joining of the POP constituent members can be reliably fixed in a short time.

Further, the pin 147A1 is formed such that the diameter of the rising portion from the rectangular plate-shaped body 147A is larger than the hole 146D formed in the holding frame 146, and when the liquid crystal panel 141R is mounted, the pin 147A1 is connected to the liquid crystal panel 141R. A gap is secured between the holding member 147 and the holding member 147. When there is no such structure, that is, when the diameter of the pin 147A1 is formed substantially the same from the base end to the tip, when the holding frame 146 is attached to the holding member 147,
The gap cannot be secured, and the holding frame 146 and the holding member 14
The adhesive for fixing 7 and 7 spreads on the end surface of the holding frame 146 due to surface tension and adheres to the display surface of the liquid crystal panel 141R.

The pedestal 145 and the holding frame 146 described above
The holding member 147 is made of a magnesium alloy having high thermal conductivity in order to improve the cooling efficiency of the liquid crystal panel 141R and the emission side polarization plate 143.

[2-2. Structure of Head Body] FIG. 4 is an overall perspective view showing the structure of the head body 150 of the optical device 140. As shown in FIG. 4, the head body 150 is a side surface substantially L-shaped structure made of magnesium alloy or the like.
Optical device main body installation portion 15 formed on the upper side of the letter-shaped horizontal plane
1, an incident side polarizing plate holding portion 152 that is formed so as to surround the optical device main body installation portion 151 and holds the incident side polarizing plate 142 on the light beam incident side, and is formed on the outer side of the vertical surface having a substantially L-shaped side surface. And a projection lens installation section 153.

The optical device main body installation section 151 includes the head body 1.
Above the horizontal plane of 50, the projection lens installation portion 15
It is formed in a substantially square shape in the central portion in the vicinity of 2. The optical device body installation portion 151 has fixing holes 151A corresponding to the mounting portions 145A and the positioning pins 145B formed on the pedestal 145 of the optical device body 140A.
And a positioning hole 151B are formed. In addition, the optical device main body installation section 151 and the incident side polarization plate holding section 1
Between the optical device main body 140A and the optical device main body 52, an opening 151C is formed at a position corresponding to the optical modulator 141 in a state where the optical device main body 140A is installed in the optical device main body installation part 151.

By installing the optical device body 140A on the optical device body installation portion 151, the optical device 140 is formed as shown in FIG. The PO mentioned above
In the optical device body 140A having the P structure, when the liquid crystal panels 141R, 141G, and 141B are adhesively fixed to the cross dichroic prism 144, focus adjustment, alignment adjustment, and fixation of the liquid crystal panels 141R, 141G, and 141B are performed. Need to be done at about the same time. Regarding the manufacturing operation of this optical device 140,
It will be described later.

The incident-side polarization plate holder 152 projects from the horizontal surface of the head body 150 so as to surround the optical device body 140A on three sides when the optical device body 140A is installed in the optical device body installation portion 151. Is formed. In this way, by forming the incident side polarizing plate holding portion 152 integrally with the head body 150, the heat generated in the incident side polarizing plate 142 can be efficiently generated and the incident side polarizing plate holding portion 1 can be efficiently generated.
The heat can be dissipated to 52 and the head body 150, and the cooling efficiency of the incident side polarization plate 142 is improved. The incident side polarization plate holding section 152 has a support section 152A for supporting the incidence side polarization plate 142, and an opening section 152B is formed at a substantially central portion. That is, the light source lamp 1
The light flux emitted from 11A passes through the incident side polarization plate 142, passes through the opening 152B, and enters the optical device body 140A.

The projection lens installation section 153 is used for the head body 15
It is located on the outside of the vertical plane of 0 and is formed in a substantially rectangular shape.
Fixing holes 153A for fixing the projection lens 160 are formed at the four corners. In addition, a positioning projection 153B for positioning the projection lens 160 is formed near the fixing hole 153A in a diagonal position so as to project from the end surface. In the projection lens 160,
As shown in FIG. 2, holes 160A and 160B are provided corresponding to the fixing holes 153A and the positioning protrusions 153B.
The projection lens 160 is accurately positioned with respect to the optical device main body 140A by engaging the hole 160B with the positioning protrusion 153B.
The projection lens 160 and the head body 150 are integrally fixed by inserting a screw into and screwing into the fixing hole 153A.

Further, the projection lens 160 is fixed to the projection lens installation portion 153 of the head body 150, and the optical device 14
0 and the projection lens 160 are integrated with each other, a screw is inserted into a fixing hole 154 formed on the horizontal surface of the head body 150, and is fixed to the light guide as the optical component casing.

[3. Structure of optical device manufacturing apparatus] Next,
The optical device manufacturing apparatus 2 will be described with reference to FIGS. FIG. 5 is a side view showing the manufacturing apparatus 2 of the optical device 140. FIG. 6 is a schematic view of the manufacturing apparatus 2 of the optical device 140 viewed from above. Optical device 14 according to the present invention
As shown in FIGS. 5 and 6, the manufacturing apparatus 2 of 0 adjusts the relative position between the liquid crystal panels 141R, 141G, and 141B and fixes the liquid crystal panels 141R, 141G, and 141B to the cross dichroic prism 144. Is a machine for manufacturing the optical device 140 by doing so, and includes the UV light shielding cover 20, the manufacturing unit main body 30, and the light flux detecting device 40.
And a computer 70 (FIG. 12), an adjusting light source device (not shown), and a fixing ultraviolet light source device as a positioning and fixing portion.

The UV light-shielding cover 20 includes a side plate 21 surrounding the upper part of the manufacturing section main body 30, a bottom plate 22, and a mounting table 25 provided at the lower part. The side plate 21 is provided with a door (not shown) that can be opened and closed. The door is provided for supplying and removing the optical device 140 and for adjusting the manufacturing unit main body 30. It is made of an acrylic plate that does not transmit ultraviolet rays. Further, the mounting table 25 is provided with casters 25A at a lower portion thereof so that the manufacturing section main body 30 can be easily moved when the apparatus is installed.

Further, the computer 70 includes the manufacturing department main body 3
0, the light flux detection device 40, the adjustment light source device, and the fixing ultraviolet light source device, and are arranged in the mounting table 25. The adjustment light source device is a light source of a light beam for position adjustment used when performing the adjustment work in the manufacturing unit main body 30, and is arranged in the mounting table 25. The fixing ultraviolet light source device includes liquid crystal panels 141R, 141G, 1
41B is a light source of a light flux (ultraviolet ray) for fixing which is used for curing the ultraviolet curable adhesive when fixing 41B on the cross dichroic prism 144.
It is located within 5.

[3-1. Structure of Manufacturing Department Main Body] The manufacturing department main body 30 supports and fixes the optical device 140, and each liquid crystal panel 1
41R, 141G and 141B are mutually adjusted in position and each liquid crystal panel 141R, 141G and 141B is adjusted to an appropriate position with respect to the cross dichroic prism 144, and the 6-axis position adjustment unit 31 and
And a supporting jig 33 for supporting and fixing the optical device 140.

[3-1A. Structure of Six-Axis Position Adjusting Unit] FIG. 7 is a side view showing the structure of the six-axis position adjusting unit 31. The 6-axis position adjusting unit 31 adjusts the arrangement positions of the liquid crystal panels 141R, 141G, and 141B with respect to the light flux incident end surface of the cross dichroic prism 144. This 6-axis position adjusting unit 31
As shown in FIG. 7, a flat surface position adjusting portion 311 installed movably along the rail 351 of the bottom plate 22 of the UV light shielding cover 20, and an in-plane rotational position adjusting portion provided at a tip portion of the flat surface position adjusting portion 311. A portion 313, an out-of-plane rotational position adjusting portion 315 provided at the tip of the in-plane rotational position adjusting portion 313, and a liquid crystal panel holding portion 317 provided at the tip of the out-of-plane rotational position adjusting portion 315. There is.

The plane position adjusting section 311 is a section for adjusting the advancing / retreating position and the plane position of the cross dichroic prism 144 with respect to the light beam incident end surface, and the base section 311A slidably provided on the mounting table 25 and the base section 311.
A leg portion 311B is provided upright on A, and a connection portion 311C is provided at an upper end portion of the leg portion 311B and to which an in-plane rotational position adjusting portion 313 is connected. Base 311A
Is driven by a drive mechanism such as a motor (not shown).
5 in the Z-axis direction (left-right direction in FIG. 7). Leg 31
1B is moved in the X-axis direction (direction orthogonal to the plane of FIG. 7) with respect to base 311A by a drive mechanism (not shown) such as a motor provided on the side. The connecting portion 311C is connected to the leg portion 311B by a driving mechanism such as a motor (not shown).
With respect to the Y axis direction (vertical direction in FIG. 7).

The in-plane rotational position adjusting portion 313 is a portion for adjusting the in-plane rotational position of the liquid crystal panels 141R, 141G, 141B with respect to the light beam incident end face of the cross dichroic prism 144, and the tip portion of the plane position adjusting portion 311. A cylindrical base 313A fixed to the base 313A and a rotation adjusting unit 313B rotatably provided in the circumferential direction of the base 313A. Then, this rotation adjusting unit 313
By adjusting the rotational position of B, the in-plane rotational position of the liquid crystal panels 141R, 141G, 141B with respect to the light beam incident end surface of the cross dichroic prism 144 can be adjusted with high accuracy.

The out-of-plane rotational position adjusting section 315 is a portion for adjusting the out-of-plane rotational position of the liquid crystal panels 141R, 141G and 141B with respect to the light beam incident end surface of the cross dichroic prism 144. This out-of-plane rotational position adjustment unit 3
15 is fixed to the tip portion of the in-plane rotational position adjusting portion 313, and has a base portion 315A having a concave curved surface which is a circular arc in the horizontal direction formed at the tip portion, and the concave curved surface of the base portion 315A is curved along the arc. And a first adjusting portion 315B having a concave curved surface that is circularly arcuate in the vertical direction formed at the tip portion, and is provided slidably along the circular arc on the concave curved surface of the first adjusting portion 315B. The second adjusting unit 315C is provided. Then, when a motor (not shown) provided on the side of the base portion 315A is rotationally driven, the first adjusting portion 315
B slides, and when a motor (not shown) provided above the first adjusting unit 315B is rotated, the second adjusting unit 315C slides and liquid crystal panels 141R, 141G, 141B with respect to the light flux incident end surface of the cross dichroic prism 144.
The out-of-plane rotational position of can be adjusted with high accuracy.

The liquid crystal panel holding portion 317 is a portion for holding the liquid crystal panels 141R, 141G, 141B to be adjusted, and it projects from the tip of the second adjusting portion 315C.
Base material 317B fixed via book pillar member 317A
And a base portion 317C screwed and fixed to the front end side of the base material 317B, and the base portion 317C is housed so that the front end portion protrudes from the base portion 317C.
Pad 317D as an adsorbing part that abuts G, 141B
And each liquid crystal panel 141 via the pad 317D.
Suction device 317 for vacuum-adsorbing R, 141G, 141B
E and. Further, the base material 317B and the base portion 317C of the liquid crystal panel holding portion 317 are the four optical fibers 3
17F, through the liquid crystal panels 141R, 141G, 14
The light source for adjustment and the light source device for fixation which supply the light flux for position adjustment and the light flux for fixation to 1B are connected.

FIG. 8 shows the base portion 3 of the liquid crystal panel holding portion 317.
It is the figure which looked at 17C from the front. The base portion 317C is a hollow member having a convex cross section with a central portion protruding, and the rectangular image formation of the liquid crystal panels 141R, 141G, 141B is formed on the substantially central portion of the rectangular tip surface of the protruding portion 3171. An adjustment light source hole 317C1 set according to a corner portion of the area, and a light beam irradiation unit arranged outside the adjustment light source hole 317C1 and set according to positions of holes 146D at four corners of the holding frame 146. Fixing light source hole 317C
2 and inside the adjustment light source hole 317C1
A cross-shaped hole 317 for exposing the pad 317D.
C3 and are formed.

The adjusting light source hole 317C1 and the fixing light source hole 317C2 are brought into contact with the tip end portion of the optical fiber 317F, and are passed through the optical fiber 317F from the adjusting light source device and the fixing light source device installed in the mounting table 25. A luminous flux is introduced. In addition, this fixing light source hole 317C
The luminous flux emitted from the second frame 2 has holes 14 at the four corners of the holding frame 146.
This is for irradiating the 6D position, that is, for holding and fixing the holding frame 146 and the holding member 147 via the pin 147A1. Further, in the projecting portion 3172 projecting to the outside on the rear side of the base 317C, the four screw holes 3
17C4 are formed, and these four screw holes 317C are formed.
By inserting a screw into the base 4, the base portion 317C becomes the base material 3
It is screwed to 17B.

The pad 317D is a porous elastic member that is expandable and contractible, and has a main body portion (not shown) housed in the base portion 317C and a predetermined amount protruding from the main body portion. The cross hole 317C3
Cross part 317D formed in a cross shape with dimensions corresponding to
1 and 1. Such a pad 317D has a base 317.
When attached to C, the cross portion 317D1 projects from the tip surface of the base portion 317C. For this reason,
Each of the liquid crystal panels 141R, 141G and 141B has a base 3
17C, but not the cross portion 31 of the pad 317D.
Contact only 7D1.

Although not specifically shown, the suction device 317E has a predetermined air hose 317 as shown in FIG.
The liquid crystal panels 141R, 141G, 141 are connected to the vicinity of the base 317C and the pad 317D via E1.
B is held on the pad 317D by vacuum suction. It should be noted that the suction device 317E includes the liquid crystal panel 141.
The suction sensor 317E2 is provided as a suction state detecting unit that detects the suction pressure of R, 141G, 141B. The suction sensor 317E2 is connected to the computer 70 and detects the suction pressure to control the suction device 317E. ing.

In FIG. 9, the optical device 14 is attached to the support jig 33.
It is an enlarged view of the manufacturing department main body 30 showing a state in which 0 is installed. The base portion 317C of the liquid crystal panel holding portion 317 described above
Has a smaller outer shape than the opening 152B formed in the incident side polarization plate holding portion 152 of the head body 150 that constitutes the optical device 140, and the liquid crystal panel holding portion 317 causes the liquid crystal panels 141R, 141G, and When sucking and holding 141B, the base portion 31 of the liquid crystal panel holding portion 317 is held.
7C is inserted into the opening 152B while the pad 3
17D and liquid crystal panels 141R, 141G, and 141B are brought into contact with each other to be held by suction.

[3-1B. Structure of Support Jig] Hereinafter, the structure of the support jig 33 will be described with reference to FIGS. 5, 9, and 10. The support jig 33, as shown in FIG.
2, a substrate 331 installed on the substrate 2, a leg portion 333 erected on the substrate 331, a set plate provided on the leg portion 333, on which the optical device 140 and a light guide portion 45 described later are attached. And 335. On the upper surface of the set plate 335 of the support jig 33, which is positioned on the rear side with respect to the optical device 140 to be installed, for fixing as a light beam irradiation unit for fixing the holding member 147 and the cross dichroic prism 144. A light source 334 is provided.

The fixing light source 334 guides the light flux from the fixing light source device installed in the mounting table 25 to the upper side of the optical device 140, and projects upward from the rear side of the set plate 335. The supporting portion 334A provided and the supporting portion 3
An arm portion 334 that extends forward from the tip of 34A toward the optical device 140 and is bent downward.
B and the base material 33 installed at the tip of the arm portion 334B
4C and the light source device for fixation are connected, and the tip is the base material 334C.
And an optical fiber 334D protruding from the optical fiber. The support portion 334A, the arm portion 334B, and the base material 334C are hollow members, hold the optical fiber 334D, and guide the fixing light flux emitted from the fixing light source device.

As shown in FIG. 9, holes 334 are formed in the base material 334 C along the outer shape of the cross dichroic prism 144, two positions at each side position, that is, a total of 6 positions.
C1 is formed, and the tip portion of the optical fiber 334D projects from the hole 334C1. That is,
The tip portion of the optical fiber 334D is positioned above the cross dichroic prism 144 and is positioned at the light flux incident end surface position of the cross dichroic prism 144, and by irradiating the light flux incident end surface position with the light flux from the fixing light source device. The cross dichroic prism 144 and each holding member 147 are bonded and fixed at two places on each side surface, that is, at six places.

Further, as shown in FIG. 9, a support piece 336 is arranged on the set plate 335 so as to face the opening 151C of the head body 150 when the optical device 140 is set.
Is connected to the computer 70 serving as a support piece control means, and the support piece 336 is connected to the set plate 335 in the vertical direction (see FIG.
Actuator 33 that controls to move back and forth in the middle up and down direction)
7 and 7.

FIG. 10 is a perspective view showing the structure of the support piece 336. The support piece 336 supports the weight of the light modulation device 141 from below and also supports the liquid crystal panels 141R and 14R.
The initial positions of 1G and 141B are set, and the positioning portion 336A serving as the external position reference surface that abuts on the end surface of the optical modulator 141 (the end surface of the holding frame 146) and the tip end portion on the bottom surface of the positioning portion 336A. Fixed movable part 3
36B and.

The positioning portion 336A includes a bottom surface portion 336A1 that abuts the bottom surface of the holding frame 146, a side surface portion 336A2 that abuts a side surface of the holding frame 146, and a front surface portion 336A3 that abuts a light flux incident end surface of the holding frame 146. , Cross section L
It is formed in a letter shape. This positioning portion 336A supports the holding frame 146 from below at the bottom surface portion 336A1 when installing the light modulation device 141 on the cross dichroic prism 144 in the process of manufacturing the optical device 140, and at the same time the side surface portion 336A2 and By bringing the front portion 336A3 and the holding frame 146 into contact with each other, the initial positions of the cross dichroic prism 144 of the liquid crystal panels 141R, 141G, and 141B with respect to the light flux incident end face are positioned in the left-right direction, the front-rear direction, and the vertical position. .

The movable portion 336B is a columnar member formed in a substantially columnar shape. The tip portion is fixed to the bottom surface portion 336A1 of the positioning portion 336A, the base end portion is connected to the actuator 337, and the actuator 337 is controlled. As a result, the set plate 335 is moved in the vertical direction (vertical direction in FIG. 9).

[3-2. Structure of Light Flux Detection Device] Hereinafter, the light flux detection device 40 will be described with reference to FIGS. 5, 9, and 11. FIG. 11 is a schematic diagram of the light flux detection device 40, and specifically, a diagram viewed from the XI-XI line direction in FIG. 9. As shown in FIG. 5, the light flux detection device 40 includes a CCD camera 41, a moving mechanism 43 configured to allow the CCD camera 41 to move three-dimensionally, and a light guide portion 45 mounted on the support jig 33. Is equipped with.

The CCD camera 41 includes a charge coupled device (Char
ge Coupled Device) is an area sensor that takes in the light beam for position adjustment emitted from the cross dichroic prism 144 and outputs it as an electric signal. In this embodiment, as schematically shown in FIG. 9 or 11, four CCD cameras 41 are arranged on four sides of the light guide section 45 via the moving mechanism 43 (FIG. 5). At this time, as shown in FIG. 11, the CCD cameras 41 are arranged corresponding to the diagonals of the rectangular image forming areas formed on the liquid crystal panels 141R, 141G, and 141B. The CCD camera 41 is provided with a zoom / focus mechanism in order to detect a projected image with high accuracy, and the zoom / focus can be freely adjusted by remote control.

Although not specifically shown in the drawings, the moving mechanism 43 has a support column which is erected on the substrate 331 of the supporting jig 33.
The CCD camera 4 includes a plurality of shaft members provided on the column and a camera mounting portion provided on the one shaft member.
1 can be moved in the X-axis direction (the horizontal direction in FIG. 11) and the Y-axis direction (the vertical direction in FIG. 11). Then, these movements are performed by a servo control mechanism inside the mounting table 25.

The light guide portion 45 is composed of the liquid crystal panels 141R and 14R.
It is composed of four beam splitters 451 as reflection mirrors arranged corresponding to the four corners of the rectangular image forming areas of 1G and 141B, and a holding cover 452 for holding each beam splitter 451 at a predetermined position. As shown in FIG. 9, the light guide section 45 causes the beam splitters 451 to convert the light fluxes at the four corners emitted from the cross dichroic prism 144 by being irradiated onto the liquid crystal panels 141R, 141G, and 141B from the six-axis position adjusting unit 31. After being refracted by 90 °, it has a function of guiding light to the CCD camera 41. The holding cover 452 is provided with an appropriate opening for transmitting the light beam refracted outward. Further, FIG. 9 shows a case where the liquid crystal panel 141G is irradiated with a light beam. With such a light guide unit 45, the light fluxes at the four corners emitted from the cross dichroic prism 144 are directly captured by the CCD cameras 41 arranged in all directions, without being projected on the screen as in the conventional case.

Here, FIG. 12 is a diagram schematically showing the manufacturing apparatus 2 of the optical device 140. As shown in FIG. 12, the manufacturing section main body 30 and the luminous flux detection device 40 described above are provided.
Are electrically connected to the computer 70. The computer 70 includes a CPU, a storage device, and the like, and forms a six-axis position adjusting unit 31.
7, suction control, 6-axis position adjustment unit 31, support jig 3
The operation control of the support piece 336 of No. 3 and the light flux detection device 40 and the image processing of the light flux detected by the CCD camera 41 of the light flux detection device 40 are performed.

[4. Manufacturing Operation of Optical Device] Next, in the manufacturing device 2 of the optical device, the liquid crystal panels 141R, 141G, and 14 for the cross dichroic prism 144 are provided.
A method of manufacturing the optical device 140 by adjusting the position of 1B will be described with reference to the flowcharts shown in FIGS. 3, 9, and 13.

First, the prism unit 180 (FIG. 3) is assembled by the steps (A) and (B) below, and the head body 1 is assembled.
Fix at 50. (A) The pedestal 145 is fixed to the lower surface of the cross dichroic prism 144 with an adhesive, and the prism unit 1
Assemble 80. (B) The prism unit 180 is fixed to the optical device main body installation portion 151 of the head body 150 by using the mounting portion 145A of the pedestal 145 fixed to the lower surface of the cross dichroic prism 144.

(C) Next, the prism unit 180
The head body 150 having the fixed
3 (S1). (D) The computer 70 controls the actuator 337, raises the support piece 336 through the opening 151C formed in the optical device main body installation portion 151 of the head body 150, and projects the support piece 336 from the bottom surface of the head body 150. (S2).

Next, the panel unit 190 (FIG. 3) is assembled by the steps (E) and (F). (E) The emission side polarization plate 143 is fixed by double-sided tape or adhesive so as to be engaged with the engagement groove 147A3 of the holding member 147. (F-1) The liquid crystal panels 141R, 141G, and 141B are housed in the housing body 146A of the holding frame 146, and the liquid crystal panels 141R, 141G, and 141B are positioned by using the outer periphery of the light-transmitting dustproof plate fixed to the counter substrate 141D. The housing 146A and each liquid crystal panel 141R, 141G, 141B using a conductive adhesive.
Stick and. Then, the support plate 146B of the holding frame 146
From the liquid crystal panel insertion side of the container 146A,
Each liquid crystal panel 141R, 141G, 141B is pressed and fixed and held. The support plate 146 for the container 146A
B can be attached by engaging the hook 146B1 of the support plate 146B with the hook engaging portion 146A1 of the container 146A. (F-2) Each liquid crystal panel 141R, 141G, 141B
The hole 146D of the holding frame 146 accommodating the
7 pin 147A1 is inserted with UV curable adhesive.

Next, the pin 147A of the holding member 147.
1 is coated with an ultraviolet curable adhesive (adhesive coating step: S3), and the panel unit 190 is mounted on the light flux incident end surface of the cross dichroic prism 144 as described below (light modulator). Placement process: S
4). (G) The panel unit 190 is inserted between the light flux incident end surface of the cross dichroic prism 144 and the incident side polarization plate holding portion 152 of the head body 150, and the holding member 147 is attached to the light flux incident end surface of the cross dichroic prism 144.
The end surface on the side opposite to the pin 147A1 is attached via an ultraviolet curable adhesive (S4A). In this mounted state, the panel unit is supported from below by the support piece 336, the end face of the holding frame 146 of the panel unit is brought into contact with the positioning portion 336A of the support piece 336, and the initial positions of the liquid crystal panels 141R, 141G, 141B are changed. It is set (S4B).

(H) The 6-axis position adjusting unit is so arranged that the liquid crystal panel holder 317 of the 6-axis position adjusting unit 31 passes through the inside of the opening 152B formed in the incident side polarizing plate holder 152 of the head body 150. 31 forward (Fig. 9),
The light flux incident end faces of the liquid crystal panels 141R, 141G, and 141B are brought into contact with the pads 317D of the liquid crystal panel holding portion 317 (S5).

(I) The suction device 317E is operated, and the liquid crystal panels 141R, 141G and 14 are operated by the pad 317D.
1B is adsorbed and held (adsorption holding step: S6). In this state, the suction sensor 317E2 of the suction device 317E senses the suction pressure of the liquid crystal panels 141R, 141G, 141B. If the suction pressure is equal to or higher than the predetermined suction pressure, the computer 70
The actuator 337 is controlled to lower the support piece 336 (support release step: S7). (J) In a state where the ultraviolet curable adhesive is uncured, a light beam is introduced from the adjustment light source hole 317C1 into the image forming area of the liquid crystal panels 141R, 141G, 141B, and the light beam emitted from the cross dichroic prism 144 is directly While checking, the advancing / retreating position, the plane position, and the rotation position of the cross dichroic prism 144 with respect to the light incident end face are adjusted to adjust the liquid crystal panels 141R, 141G, 141B.
Focus / alignment adjustment is performed (position adjustment step: S8).

Specifically, the liquid crystal panels 141R and 141
The focus and alignment adjustments for G and 141B are shown in FIG.
This is performed based on the flow chart shown in FIG. Using a master unit having a POP structure in which the focus position and alignment position are adjusted in advance based on the characteristics of the projection lens 160 for each model, the CCD camera 41 is moved to a position where the light flux emitted from the master unit can be reliably received. Then, the position of the CCD camera 41 is registered as a reference position. At this time, the master unit is formed by integrally forming three reference liquid crystal panels for each color light as reference light modulators on a reference cross dichroic prism as a reference color combining optical device.

The image picked up by the CCD camera 41 at this time is also registered. As this image, for example, FIG.
As shown in, a plurality of pixel areas CA corresponding to the four corners of the reference liquid crystal panel are displayed. Then, this image shows the liquid crystal panels 141R, 141G,
It becomes a reference pattern when the position of 141B is adjusted. The image captured by the CCD camera 41 is the display screen 7 on the display of the computer 70 shown in FIG.
It is displayed in 1. The display screen 71 has a CCD camera 41.
The image display view 72 for directly displaying the video from the image, the image processing view 73 for performing the pattern matching processing on the image displayed in the image display view 72 based on the reference pattern image, and the result of the image processing, Axis movement amount display view 74 for displaying each axis adjustment amount of the position adjustment unit 31
It has and. In addition, the reference pattern and CCD
The reference position of the camera 41 is registered in the storage unit of the computer 70 as model data corresponding to the model.

(J-1) After the support releasing step S7,
From the computer 70, the cross dichroic prism 144 and the liquid crystal panels 141R, 141G to be adjusted,
The model data registered in advance according to the model of 141B is called, and the CCD camera 41 is moved to the reference position and set (S81). (J-2) Thereafter, for example, first, the liquid crystal panel 141G is irradiated with a light beam for position adjustment from the six-axis position adjusting unit 31, and focus adjustment of the liquid crystal panel 141G with respect to the light beam incident end surface of the cross dichroic prism 144 is performed (S82). ). Specifically, the CCD camera 41 first captures the images of the four corners of the liquid crystal panel 141G, and combines them by using specific index values (edge strength) in the outer peripheral portion of the image area CA from the captured images. It is determined whether or not it is in focus, and the quality of focus is checked. The 6-axis position adjusting unit 31 is controlled based on the index values of the four corners, and the liquid crystal panel 141G is located at a position where the index values of the four corners are almost equal and the largest.
By adjusting the Z direction (the direction in which the cross dichroic prism 144 is close to and separated from the cross dichroic prism 144).

(J-3) Next, the alignment of the liquid crystal panel 141G is adjusted (S83). Specifically, on the display screen 71 of the program, STAGE1 (STAGE2, STAGE2, STAGE2, ST that represents the 6-axis position adjustment unit 31 that holds the liquid crystal panel 141G
AGE3 is selected) (corresponding to the 6-axis position adjusting unit 31 that holds the liquid crystal panels 141R and 141B), and the CCD camera 41 captures images at the four corners of the liquid crystal panel 141G. Here, on the display screen 71 of the computer 70, the image captured by the CCD camera 41 is displayed on the screen display view 72, and the measured data of STAGE 1 after image processing is displayed on the image processing view 73. To be done.

In this state, Measures in the image processing view 73
When the ent button is pressed, a portion corresponding to the reference pattern on the image processing view 73 is detected, the position of the detected reference pattern on the screen is detected, and the detection result is a reference pattern image registered in advance. Is calculated and the result is displayed in the axis movement amount display view 74 as the movement amount of each axis of the 6-axis position adjusting unit 31.
Then, the computer 70 displays the axis movement amount display view 74.
The 6-axis position adjusting unit 31 is controlled based on the respective axial movement amounts displayed on the screen, and the plane position, the in-plane rotational position, and the out-of-plane rotational position of the liquid crystal panel 141G are adjusted. (J-4) Once the adjustment is completed, measuremen again
By pressing the t button, the movement amounts of the respective axes are calculated, and the movement amounts of all the axes are adjusted to approximately 0, and the alignment of the liquid crystal panel 141G is adjusted (S84). The focus / alignment adjustment of the liquid crystal panels 141R, 141G, 141B is first performed on the liquid crystal panel 141G.
Subsequently, the liquid crystal panels 141R and 141B are performed.

(K) When proper focus alignment is obtained, the adhesive is completely cured (positioning step: S9). Specifically, from the fixing light source holes 317C2 formed in the base portion 317C to the holes 1 at the four corners of the holding frame 146.
The position 46D is irradiated with ultraviolet rays, and the holding frame 146 and the holding member 147 are adhesively fixed via the pin 147A1 (S9).
A), from the fixing light source 334 provided on the leg 333,
Holding member 147 and cross dichroic prism 144
Ultraviolet rays are radiated to the joint portion between and, and the panel unit 190 and the cross dichroic prism 144 are bonded and fixed (S9B).

(L) Stop the operation of the suction device 317E,
The liquid crystal panel holding portion 317 is retracted (S10), and pixel shift measurement is performed (S11) to confirm the positions of the liquid crystal panels 141R, 141G, and 141B. Specifically, a luminous flux is introduced from the adjustment light source hole 317C1 into the image forming area of each liquid crystal panel 141R, 141G, 141B,
Check the pixels in the combined image and check each liquid crystal panel 1
The positions of 41R, 141G and 141B are confirmed. (M) 6-axis position adjustment unit 3 after the pixel shift measurement
1 is retracted, and the optical device 140 is removed (S12).
The optical device 140 is manufactured through the above steps.

[5. Effects of Embodiment] According to the present embodiment as described above, there are the following effects. (1) The manufacturing apparatus 2 includes a support jig 33, a 6-axis position adjusting unit 31, and a fixing light source device.
Since the setting plate 335 has the supporting piece 336, when the panel unit 190 is attached to the light flux incident end surface of the cross dichroic prism 144 by using the ultraviolet curable adhesive, the surface tension by the adhesive is increased. Even when the weight of the panel unit 190 cannot be held only by itself, the weight of the panel unit 190 is not supported by the support piece 336.
It is possible to maintain the mounting state of the cross dichroic prism 144 of the panel unit with respect to the light flux incident end surface. Therefore, when manufacturing the optical device 140, the position adjustment is performed by the 6-axis position adjustment unit 31 from the state in which the panel unit 190 is mounted on the light flux incident end surface of the cross dichroic prism 144, and the cross dichroic prism 144 is fixed by the fixing light source device. Since the panel unit 190 can be positioned and fixed to the light flux incident end surface of the optical device 140, the optical device 140 can be manufactured even when the head body 150 has a complicated shape.

(2) Since the support piece 336 is capable of projecting and retracting in the vertical direction of the set plate 335, the support piece 336 is formed.
The panel unit 190 is supported by the panel unit 190 to secure the mounting state of the cross dichroic prism 144 of the panel unit 190 to the light flux incident end face, and from the mounted state, the six-axis position adjusting unit 31 shifts the cross dichroic prism 144 to the light flux incident end face of the cross dichroic prism 144. On the other hand, when adjusting the positions of the liquid crystal panels 141R, 141G, and 141B,
By lowering the support piece 336, the support piece 336 can be moved to a position where it does not interfere with the panel unit 190, and the liquid crystal panel 14 by the 6-axis position adjustment unit 31.
The positions of 1R, 141G and 141B can be smoothly adjusted.

(3) The support piece 336 has a positioning portion 336.
A, the positioning portion 336A has a bottom surface portion 336A.
1, the side surface portion 336A2, and the front surface portion 336A3, the panel unit 190 is supported by the support piece 336, that is, the holding frame 146.
End surfaces of the bottom surface portion 336A1, the side surface portion 336A2,
Also, the initial positions of the liquid crystal panels 141R, 141G, and 141B with respect to the light flux incident end surface of the cross dichroic prism 144 can be set in a state of being in contact with the front surface portion 336A3.

Therefore, the liquid crystal panels 141R, 141G, 141B with the panel unit 190 mounted on the light-incident end surface of the cross dichroic prism 144.
By setting the initial position of the liquid crystal panels 141R, 141G, and 141B, which is usually performed by the 6-axis position adjusting unit 31, the rough adjustment of the liquid crystal panels 141R, 141G, and 141B with respect to the light incident surface of the cross dichroic prism 144 can be omitted. It is possible to reduce the cycle time of the position adjusting step S8 performed by the shaft position adjusting unit 31.

(4) The optical device 140 includes the head body 150.
An opening 151C is formed in the head body 150, and when the optical device 140 is installed on the support jig 33, the support piece 336 is disposed so as to face the opening 151C. Through 151C, support piece 33
You can move 6 forwards and backwards. (5) The 6-axis position adjusting unit 31 includes the suction device 317E.
By including the pad 317D connected to the suction device 317E, even if the outer shape of the holding frame 146 forming the light modulator 141 becomes complicated,
The suction device 317E and the pad 317D attract the light flux incident end faces of the liquid crystal panels 141R, 141G, and 141B, so that the liquid crystal panels 141R, 141G, and 141 are attracted.
B can be held, and the structure for holding the liquid crystal panels 141R, 141G, and 141B of the 6-axis position adjustment unit 31 can be simplified.

(6) The suction device 317E is the suction sensor 3
By including 17E2, the suction pressure of the liquid crystal panels 141R, 141G, 141B by the suction device 317E is detected by the suction sensor 317E2, and the liquid crystal panel 1
The holding state of 41R, 141G, 141B can be accurately grasped. Therefore, when the suction pressure by the suction device 317E is reduced, it can be detected by the suction sensor 317E2, and the holding state of the panel unit 190 cannot be ensured due to the shortage of the suction pressure, and the pad 317D.
It is possible to prevent the panel unit 190 from separating from and dropping and damaging the liquid crystal panels 141R, 141G, and 141B.

(7) Since the manufacturing apparatus 2 is equipped with the computer 70, the supporting piece 336 is lowered according to the suction pressure detected by the suction sensor 317E2.
Support piece 336 and panel unit 190 (holding frame 146)
Can be separated from. Therefore, the suction device 3
Set a stable suction pressure by 17E and set the suction sensor 31
If the suction pressure sensed by 7E2 is equal to or higher than the set suction pressure, the computer 70 lowers the support piece 336.
The support piece 336 can be lowered in a state where the holding state of the panel unit 190 by E is stably ensured.

(8) Base 3 of 6-axis position adjusting unit 31
A fixing light source hole 317C2 is formed in 17C, and the tip portion of the optical fiber 317F connected to the fixing light source device is brought into contact with the fixing light source hole 317C2.
After adjusting the positions of the liquid crystal panels 141R, 141G, and 141B, a light flux can be emitted from the fixing light source hole 317C2 through the hole 146D of the holding frame 146, and the holding member 147 and the holding frame 146 can be adhesively fixed.

(9) A fixing light source 334 is installed on the upper surface of the setting plate 335 of the supporting jig 33.
4 is a support portion 334A, an arm portion 334B, a base material 334C,
By including the optical fiber 334D connected to the fixing light source device, even if the holding member 147 is interposed between the light modulator 141 and the cross dichroic prism 144, the panel unit 190 and A light flux is emitted from the optical fiber 334D between the cross dichroic prism 144 and the panel unit 19
0 and the cross dichroic prism 144 can be adhesively fixed.

(10) The method of manufacturing the optical device 140 includes an adhesive applying step S3, an optical modulator arranging step S4, a suction holding step S6, a support releasing step S7, a position adjusting step S8, and a positioning step S9. As a result, the pin 147A of the holding member 147 that forms the panel unit 190 is formed.
While applying an ultraviolet curable adhesive to the end surface on the side opposite to 1, supporting the panel unit 190 with the support piece 336,
An ultraviolet curable adhesive is closely attached to the light flux incident end surface of the cross dichroic prism 144, and the panel unit 190 is attached.
Are arranged to secure the holding state of the panel unit 190, and the next step (adsorption holding step S6, support releasing step S7,
It is possible to shift to the position adjusting step S8 and the positioning step S9). Therefore, even if the shape of the head body 150 is complicated or the weight of the panel unit 190 is increased as the cooling performance of the projector 100 is improved, the optical device 140 can be manufactured smoothly.

(11) In the optical modulator arranging step S4, the liquid crystal panel 14 is moved by the positioning portion 336A of the supporting piece 336.
By performing the initial setting (S4B) of 1R, 141G, and 141B, in the optical modulator arranging step S4,
With the panel unit 190 mounted on the cross dichroic prism 144, the panel unit 190 (liquid crystal panels 141R, 141G, 141B) can be arranged at a predetermined design position, and in the position adjusting step S8, the cross dichroic prism 144 is Rough adjustment of the liquid crystal panels 141R, 141G, and 141B with respect to the light flux incident end surface can be omitted, the manufacturing process of the optical device 140 can be shortened, and the optical device 140 can be manufactured smoothly.

(12) The liquid crystal panel 141 is provided with the suction holding step S6 and the support releasing step S7.
When adsorbing and holding R, 141G, 141B, the adsorbing pressure of the liquid crystal panels 141R, 141G, 141B is detected,
When the suction pressure becomes equal to or higher than a predetermined pressure, the support piece 336 can be lowered, so that the liquid crystal panels 141R,
With 41G and 141B securely held by suction,
The position of the liquid crystal panels 141R, 141G, 141B can be adjusted.

(13) The manufacturing method of the optical device 140 includes the positioning step S9, so that the holding member 14
7 and the holding frame 146, and the holding member 147 and the cross dichroic prism 144 can be securely bonded and fixed.

[6. Modification of Embodiments]
The present invention is not limited to the above-described embodiment, and includes other configurations and the like that can achieve the object of the present invention, and the following modifications and the like are also included in the present invention. For example, in the above-described embodiment, the positioning portion 336A of the support piece 336 has the bottom surface portion 3
36A1, side part 336A2, and front part 336A3
However, the present invention is not limited to this.
It may be configured to surround four side surfaces, the light flux incident end surface and the light flux exit end surface. That is, the positioning portion 33
6A, any configuration may be used so that the holding frame 146 can be positioned in the front-rear direction, the left-right direction, and the up-down direction with respect to the light flux incident end surface of the cross dichroic prism 144.

Further, in the above embodiment, the holding member 1
47 is a pin 147A protruding from the rectangular plate 147A.
Although it is configured to include 1, the holding frame 1 is not limited to this.
In order to accommodate 46, a standing piece extending from the rectangular plate 147A to the edge of the rectangular plate 147A may be provided. In this case, it is necessary to form the shape of the fixing light source hole 317C2 formed in the base portion 317C at a position corresponding to the standing piece.

Further, in the above embodiment, the liquid crystal panel 141 is used as an optical modulator for performing optical modulation in accordance with an image signal.
Although R, 141G, and 141B are adopted, it is not limited to this. That is, the present invention may be adopted for position adjustment of a device other than liquid crystal, such as a device using a micromirror, as an optical modulator for performing optical modulation. In addition, LCOS (li
It can also be used for quid crystal on silicon) type reflective LCD panels.

Further, in the above-described embodiment, the combined light emitted from the cross dichroic prism 144 is directly subjected to CC.
Each liquid crystal panel 14 is detected by the D camera 41.
Although the positions of 1R, 141G, and 141B have been adjusted, for example, a screen may be prepared in the latter stage of the projection lens 160, and a CCD camera may indirectly detect a projected image on the screen. . However, the above embodiment has an advantage that the manufacturing apparatus 2 for an optical device can be downsized.

Although the optical device 140 is incorporated in the projector 100 in the above embodiment, the present invention is not limited to this.
It may be mounted on other optical devices. In addition, the specific structure, shape, and the like at the time of carrying out the present invention may be other structures and the like as long as the object of the present invention can be achieved.

[0109]

As described above, according to the optical device manufacturing apparatus and the optical device manufacturing method of the present invention, the shape of the head body becomes complicated with the increase in the brightness and performance of the projector. Moreover, even if the weight of the light modulation device becomes heavy, the position of the light modulation device can be smoothly adjusted, and the optical device can be easily manufactured.

[Brief description of drawings]

FIG. 1 is a schematic view showing a structure of a projector including an optical device manufactured by an optical device manufacturing apparatus according to an embodiment of the present invention.

FIG. 2 is an external perspective view showing the structure of the optical device in the embodiment.

FIG. 3 is an exploded perspective view showing an optical device body in the embodiment.

FIG. 4 is an external perspective view showing the structure of the head body in the embodiment.

FIG. 5 is a side view showing the optical device manufacturing apparatus in the embodiment.

FIG. 6 is a schematic view of the optical device manufacturing apparatus according to the exemplary embodiment as viewed from above.

FIG. 7 is a side view showing a structure of a 6-axis position adjusting unit in the embodiment.

FIG. 8 is an enlarged view showing a main part of a liquid crystal panel holding part in the embodiment.

FIG. 9 is a cross-sectional view showing an enlarged main part of the manufacturing apparatus main body in the embodiment.

FIG. 10 is an external perspective view showing the structure of the support piece in the embodiment.

FIG. 11 is a front view schematically showing the luminous flux detection device of the manufacturing apparatus in the embodiment, and is an arrow XI-XI in FIG. 9.
It is the figure seen from.

FIG. 12 is a block diagram showing an internal structure of a computer that controls the manufacturing apparatus in the embodiment.

FIG. 13 is a flowchart showing a manufacturing operation of the optical device in the embodiment.

FIG. 14 is a flowchart showing operations of focus and alignment adjustment of the liquid crystal panel in the embodiment.

FIG. 15 is a diagram showing a reference pattern used in the embodiment.

FIG. 16 is a diagram showing a display screen for displaying an image captured in the embodiment.

[Explanation of symbols]

2 Manufacturing Equipment 31 6-axis Position Adjustment Unit (Position Adjustment Section) 33 Support Jig (Mounting Table) 70 Computer (Support Piece Control Unit) 140 Optical Device 141 Light Modulators 141R, 141G, 141B Liquid Crystal Panel (Light Modulator Main Body) 144 Cross dichroic prism (color combining optical device) 146 Holding frame 146D Hole 150 Head body (structure) 150C Opening 317C2 Fixing light source hole (light irradiation part) 317D Pad (adsorption part) 317E1 Adsorption sensor (adsorption state detection means) 334 Fixing light source (light emitting part) 336 Support piece 336A1 Bottom part (outer position reference surface) 336A2 Side part (outer position reference surface) 336A3 Front part (outer position reference surface) S3 Adhesive application step S4 Light modulator placement step S6 Suction hold step S7 Support release step S8 Position adjustment step S9 Process decided

Claims (8)

[Claims] 1. An optical device comprising: a plurality of light modulators for modulating a plurality of color lights for each color light according to image information; and a color combining optical device for combining the light fluxes modulated by the respective light modulators. Adjust the mutual position of each light modulator to manufacture,
A manufacturing apparatus of an optical device for fixing each light modulation device to a light flux incident end surface of the color synthesis optical device, comprising a mounting table on which the color synthesis optical device is mounted, and the color synthesis optical device of each light modulation device. And a position adjusting unit that adjusts the mutual position of each light modulator, and a positioning fixing unit that positions and fixes the light modulator on the light flux incident end face after adjusting the mutual position of each light modulator. The mounting table is provided with a supporting piece for supporting the light modulator from the lower side in the vertical direction, and the supporting piece is capable of projecting and retracting with respect to the mounting surface of the mounting table. Optical device manufacturing equipment. 2. The optical device manufacturing apparatus according to claim 1, wherein the optical device is provided with the color synthesizing optical device and a projection optical system for enlarging and projecting a light flux emitted from the color synthesizing optical device. An optical device, comprising: a body, an opening for cooling the light modulator is formed in the structure, and the support piece is arranged at a position corresponding to the opening. apparatus. 3. The optical device manufacturing apparatus according to claim 1 or 2, wherein the support piece is provided with an outer shape reference surface for positioning the light modulator with the outer shape reference. Characteristic optical device manufacturing equipment. 4. The apparatus for manufacturing an optical device according to claim 1, wherein the position adjusting section includes an adsorption section that adsorbs and holds the optical modulation device. An apparatus for manufacturing an optical device, comprising: an adsorption state detecting means for detecting an adsorption state of the light modulation device; and a support piece control means for controlling movement of the support piece according to the detected adsorption state. . 5. The apparatus for manufacturing an optical device according to claim 1, wherein the light modulation device is positioned by a light curable adhesive with respect to a light flux incident end face of the color combining optical device. The apparatus for manufacturing an optical device is fixed, and the positioning and fixing unit includes a light beam irradiation unit that cures the photocurable adhesive. 6. The apparatus for manufacturing an optical device according to claim 5, wherein the light modulation device includes a light modulation element body that performs light modulation, and a substantially rectangular holding frame that houses and holds the light modulation element body. A hole is formed in the four corners of the holding frame, and the light beam irradiation unit is provided in plural according to the hole positions of the four corners of the holding frame. . 7. The apparatus for manufacturing an optical device according to claim 5 or 6, wherein a fixing frame fixed by a photo-curing adhesive is provided on a light flux incident end surface of the color combining optical device, The light modulation device is fixed to the light flux incident end face via this fixing frame, and the plurality of light beam irradiation units are provided in accordance with the joint position between the light flux incident end face of the color combining optical device and the fixed frame. An optical device manufacturing apparatus characterized in that 8. An optical device comprising: a plurality of light modulators for modulating a plurality of color lights for each color light according to image information; and a color combining optical device for combining the light fluxes modulated by the respective light modulators. Adjust the mutual position of each light modulator to manufacture,
A method of manufacturing an optical device for fixing each light modulation device to a light-incident end face of the color combining optical device, comprising: an adhesive application step of applying a photocurable adhesive to the light modulation device; While supporting the light modulator coated with the agent by a support piece, a light modulator arranging step of arranging the light modulator by adhering a light curable adhesive to the light flux incident end surface of the color combining optical device, An adsorption holding step of adsorbing and holding the image forming area of the light modulation device, a support releasing step of releasing the support of the optical modulation device by the supporting piece on condition that the adsorption holding is performed, and the adsorbed and held light A position adjusting step of adjusting the position of the modulator with respect to the light beam incident end face, and irradiating the photocurable adhesive with a light beam while maintaining the adjusted position of the light modulating device, Positioning and fixing the device Method of manufacturing an optical device characterized by and a positioning step.