A microdisplay-based HUD for automotive applications: Backplane design, planarization, and optical implementation

Automotive head-up displays require compact, bright, and inexpensive imaging systems. In this thesis, a compact head-up display (HUD) utilizing liquid-crystal-on-silicon microdisplay technology is presented from concept to implementation. The thesis comprises three primary areas of HUD research: the specification, design and implementation of a compact HUD optical system, the development of a wafer planarization process to enhance reflective device brightness and light immunity and the design, fabrication and testing of an inexpensive 640 x 512 pixel active matrix backplane intended to meet the HUD requirements. The thesis addresses the HUD problem at three levels, the systems level, the device level, and the materials level.; At the systems level, the optical design of an automotive HUD must meet several competing requirements, including high image brightness, compact packaging, video-rate performance, and low cost. An optical system design which meets the competing requirements has been developed utilizing a fully-reconfigurable reflective microdisplay. The design consists of two optical stages, the first a projector stage which magnifies the display, and a second stage which forms the virtual image eventually seen by the driver. A key component of the optical system is a diffraction grating/field lens which forms a large viewing eyebox while reducing the optical system complexity. Image quality biocular disparity and luminous efficacy were analyzed and results of the optical implementation are presented.; At the device level, the automotive HUD requires a reconfigurable, video-rate, high resolution image source for applications such as navigation and night vision. The design of a 640 x 512 pixel active matrix backplane which meets the requirements of the HUD is described. The backplane was designed to produce digital field sequential color images at video rates utilizing fast switching liquid crystal as the modulation layer. The design methodology is discussed, and the example of a clock generator is described from design to implementation. Electrical and optical test results of the fabricated backplane are presented.; At the materials level, a planarization method was developed to meet the stringent brightness requirements of automotive HUD's. The research efforts described here have resulted in a simple, low cost post-processing method for planarizing microdisplay substrates based on a spin-cast polymeric resin, benzocyclobutene (BCB). Six-fold reductions in substrate step height were accomplished with a single coating. Via masking and dry etching methods were developed. High reflectivity metal was deposited and patterned over the planarized substrate to produce high aperture pixel mirrors. The process is simple, rapid, and results in microdisplays better able to meet the stringent requirements of high brightness display systems. Methods and results of the post-processing are described.