Optical Engine Design for a Compact, High-Luminance DLP Projector Using Four-Channel LEDs and a Total Internal Reflection Prism

How to obtain higher brightness with a small volume projection engine for 4K resolution digital light processing (DLP) is of great significance. In this paper, we first use the fourth channel serving as a blue pump leading to a 52% gain of green brightness. Secondly, a new inline total internal reflection prism glued with a spherical mirror is constructed to notably reduce the length of the relay illumination system by more than 10 mm, resulting in a more compact optical engine with a volume of 210 × 140 × 36 mm3. Thirdly, a projection lens is optimized with a modulation transfer function higher than 0.6 at 93 lines for a distance of 2125 mm with distortion lower than 1%. As a result, the efficiencies of RGB lights are higher than 60%, and the luminance and uniformity on the screen reach 1412 lm and 94.5% measured by the prototype. Our proposed projection system is significantly helpful for designing a compact and high-luminance 4K DLP projection.