Microlens array-based high-gain screen design for direct projection head-up displays

Head-up display (HUD) systems have been used in recent car models to provide essential information to the drivers while keeping their eyes on the road. Virtual image HUD systems have been the preferred method, but they have the drawback of requiring a large volume of space in order to accommodate the relay optics that creates the virtual image. This is especially significant as the desired field of view increases. Direct projection HUD systems have been developed with a separate stand-alone microlens array (MLA)-based transparent screen on the dashboard, offering a compact solution. In this paper, we propose a direct projection HUD system based on a unique, windshield-embedded see-through screen that uses minimal space under the dashboard, offering an elegant and compact solution to the HUD problem. The screen is based on MLAs with varying surface normal angles such that the light from the projector is directed to the viewer's eyes from all positions across the field of view. Varying tilts provide an efficient relay and high brightness even with a low-lumen output projector. The calculated screen gain is about 69 and the eyebox area is about 30 cm×30 cm.