Approaches and Prospects for Thin RPTV
A study of the technology and markets for thin rear-projection consumer television.

TABLE OF CONTENTS
1 Table of Contents 2
2 Executive Summary 6
3 Drivers for Thin Rear Projection TV 8
4 Thin Rear Projection Approaches 11
4.1. Introduction 11
4.2. Wide Field of View Projection Optics 11
4.2.1. All reflective optics 12
4.2.2. Refractive - reflective optics 13
4.2.3. All refractive optics 14
4.2.4. Light path aiming 16
4.2.5. Folding the light path 19
4.2.6. Projection lens cost 25
4.3. Approaches that Incorporate Novel Screen Components 26
4.3.1. SCRAMscreen 26
4.3.2. Hybrid Fresnel lens 28
4.3.3. Light Control Films 29
4.4. Electronic Correction of Distortion and Color Problems 30
4.5. Alternative Light Sources 33
4.5.1. LED light sources 34
4.5.2. Laser light sources 36
4.6. Orientation and Position of the Light Engine within the Enclosure 37
4.7. Conclusions Relating to Thin RPTV Technology 39
5 Wedge Projection Method 41
6 Price and Status of Commercialization 44
6.1. In Focus - RCA/Thomson 44
6.1.1. InFocus 44
6.1.2. RCA/Thomson 45
6.1.3. TLC 46
6.2. Mitsubishi 46
6.3. JVC 47
6.4. Samsung 48
6.5. Sony 49
6.6. General Product Conclusions 51
7 Analysis of Prospects 53
7.1. Introduction 53
7.2. The current large screen HDTV market 53
7.3. Thin RPTV pricing differential 60
7.4. Slim/Thin RPTV Manufacturing Cost Differential 64
7.5. Penetration Forecast and Conclusions 74
 
Table of Figures
  Figure 1: Screen size versus enclosure depth 10
  Figure 2: A projection optics concept based on two curved mirrors 12
  Figure 3: A projection optics design based on four mirrors 13
  Figure 4: An optical system that includes a refractive lens and aspheric mirror 14
  Figure 5: A projection lens based on all refractive elements and no fold 15
  Figure 6: A projection lens based on all refractive elements that has a fold prism 15
  Figure 7: An all-refractive lens with a fold mirror 16
  Figure 8: The use of an offset lens 17
  Figure 9: An offset lens in an optical system 18
  Figure 10: The video projector is angled upwards 19
  Figure 11: An optical system with a folded lens and a single flat mirror 19
  Figure 12: An optical system with an offset lens and a single curved mirror 20
  Figure 13: An optical system based on two flat mirrors 21
  Figure 14: An optical system based on two flat mirrors and an obliquely oriented light engine 21
  Figure 15: Two versions of an optical system based on one flat mirror plus one curved mirror and an offset lens 22
  Figure 16: An optical system based on two flat mirrors, one curved mirror and an obliquely oriented light engine 23
  Figure 17: An optical system based on two aspheric mirrors and one flat mirror 23
  Figure 18: An optical system based on three flat mirrors and an extra light path fold at the special screen 24
  Figure 19: An optical system based on three aspheric mirrors and one flat mirror 25
  Figure 20: The SCRAMscreen 27
  Figure 21: The SCRAMscreen in a simple optical system 27
  Figure 22: Cross sectional view of a hybrid Fresnel lens 29
  Figure 23: Diffusing light control film 30
  Figure 24: Off-axis GRIN Material 30
  Figure 25: Various types of geometrical distortion 31
  Figure 26: Lateral chromatic aberration 31
  Figure 27: Brightness non-uniformity 32
  Figure 28: Color non-uniformity 32
  Figure 29: The LED PhlatLight made by Luminus Devices 34
  Figure 30: A LED based light engine made by Sypro Optics 35
  Figure 31: Novalux Lasers as Implemented by Oerlikon 37
  Figure 32: A prototype 52" Mitsubishi RPTV having a Novalux laser light source 37
  Figure 33: Light engine orientations within the enclosure 38
  Figure 34: An optical system in which the light engine projects downwards 39
  Figure 35: In a wedge shaped waveguide a ray's direction changes each time it reflects off the side 41
  Figure 36: The display comprises a video projector, slab waveguide and wedge shaped waveguide 42
  Figure 37: A prototype wedge, thin rear projection display 43
  Figure 38: Two stylings of the In Focus thin RPTV 45
  Figure 39: The Thin RCA/Thomson RPTV 45
  Figure 40: Concept illustration of the proposed TCL thin RPTV 46
  Figure 41: The Mitsubishi Mega Wall thin RPTV 47
  Figure 42: JVCs' thin RPTV 48
  Figure 43: Samsungs' thin RPTV 49
  Figure 44: Sony's' thin prototype RPTV 50
  Figure 45: Recently announced Sony thin RPTV 50
  Figure 46: Current technology share by screen size 53
  Figure 47: Sales of Normal and Large screen TVs by geographic region 54
  Figure 48: Evolution in the sale of HDTVs by screen size 55
  Figure 49: World wide large screen HDTV unit sales projection by technology 57
  Figure 50: Projected sales of RPTV 58
  Figure 51: The ASP for large screen, flat panel HDTV as a function of time. 59
  Figure 52: The drop in large screen flat panel HDTVs is approaching a limit 59
  Figure 53: The effect of new features on the price of HDTVs 60
  Figure 54: Pricing of various HDTV technologies as a function of screen size 61
  Figure 55: Price trends in RPTV by screen size 61
  Figure 56: Pricing history of Samsung's model HL-S4676S thin RPTV 62
  Figure 57: Screen diagonal versus D/d ratio for various RPTV products 63
  Figure 58: Price versus screen diagonal for various RPTV products 64
  Figure 59: Projected DLP light engine cost as a function of HDTV thickness 65
  Figure 60: Estimated light engine cost as a function of D/d 66
  Figure 61: Engine Costs Estimated by Zeiss and Insight Media 74
  Figure 62: Proportion of RPTV sales that are thin or slim as a function of time 75
 
Table of Tables
  Table 1: Screen size versus enclosure depth 10
  Table 2: Specification accomplished by the four-mirror projection system 13
  Table 3: Specification accomplished by the reflective - refractive approach 14
  Table 4: Specification accomplished by the all-refractive lens approach 16
  Table 5: Summary of the specifications of In Focus' thin RPTV 44
  Table 6: Summary of the specifications of Mitsubishi's Mega Wall thin RPTV 47
  Table 7: Summary of the specifications of JVCs thin RPTVs 48
  Table 8: Summary of the specifications of Samsungs' thin RPTVs 48
  Table 9: Summary of the specifications of Sony' thin prototype RPTV 49
  Table 10: A summary of thin RPTVs 51
  Table 11: Global projections for large screen HDTV sales by technology 56
  Table 12: Normal RPTV with a UHP-type lamp 67
  Table 13: Slim RPTV with a UHP-type lamp 68
  Table 14: Thin RPTV with a UHP-type lamp 69
  Table 15: Normal RPTV with Laser Illumination 70
  Table 16: Slim RPTV with Laser Illumination 71
  Table 17: Thin RPTV with Laser Illumination 72
  Table 18: BOM Summary 73
 

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