Design and Optimization of 2D Laser Source Module for Compact Projector

In order to make projector compact and efficient, we propose that the 2D laser source module is consisted of VCSEL array and micro-lens array. It describes packaging structure design of VCSEL array and thermal resistance calculation. A thermal 3D analysis of 3 ×3 array based on the finite-element method (FEM) is presented. The analysis shows that the maximum internal temperature of a VCSEL array reaches 51°C. Then, it describes the principle of the micro-lens array. By ZEMAX simulation, in the micro-lens array illumination system, we have got the energy efficiency 67.3%, the light uniformity is 95.5%, respectively, on the micro-display chip at the distance of 65 mm. We have successfully built the complete 3-LCOS projection system based on the 2D source module. It can provide 1362 lm D65 light, and its total volume is 260 × 200 × 160 mm³ which is more compact than the commercial projector.