The cathode-ray-tube TV set has ruled the consumer
electronics world for decades: since its introduction,
more than a billion of them have been sold. In some
countries, households are much more likely to have a TV
than a refrigerator.
From a baroque box with a bulbous little
black-and-white screen, TVs became big, bright, and
ubiquitous. Today they not only dominate entertainment
rooms, they also perch on dressers, hang under kitchen
cabinets, fit into pockets and purses, and pop down from
the ceilings of automobiles. They got their start
snatching signals out of the air, but TVs are now apt to
be fed from cables, satellite dishes, VCRs, and DVDs,
and, increasingly, computers.
But what kind of TV will be our portal into the
digital, thousand-channel, high-definition world we've
all been waiting for? Nobody can say at the moment. But
a dazzling dark-horse candidate, the Grating Light Valve
display, exploits several extraordinarily promising
recent advancesmicroelectromechanical systems and
advanced semiconductor lasersto offer some of the most
brilliant, sharpest pictures ever to grace a glowing screen.
Ironically, amid this blossoming of the TV market, one
thing has become clear: the CRT is destined for a slow
but sure decline. The CRT is losing market share because
for TVs, more and more, size does matter. For their
entertainment rooms, consumers want big screens, and
CRTs can't satisfy: the bigger a CRT screen is, the
deeper the glass tube must be. The set becomes
impossibly heavy and unwieldy when the diagonal
measurement of the screen goes beyond about 36 inches.
That problem, and a few others, have opened the way for
a host of contenders to replace the CRT as the
centerpiece in the home of the future and to reap untold
billions in sales.
Like candidates in a presidential primary, a field of
these possible successors appeared in January at the
2004 International Consumer Electronics Show, in Las
Vegas, Nev., creating a pulsating cacophony of big,
bigger, and gargantuan images. Liquid-crystal displays,
plasma displays, non-CRT projection displays using
digital-light-processing chips or
liquid-crystal-on-silicon technologyeach had its moment
in the spotlight. All featured impressive technical
developments and big pictures. And all are vying for a
place in your living room.
But the best may very well be yet to come. Developed
by Silicon Light Machines, Sunnyvale, Calif., a
subsidiary of Cypress Semiconductor Corp., San Jose,
Calif., the Grating Light Valve (or GLV) display [see
photo] relies
on microelectromechanical systems technology to control
and direct light from semiconductor lasers to form a TV
picture on a screen or even a wall. It is licensed for
display systems by Sony Corp., Tokyo. Silicon Light,
which now manufactures and sells about a thousand GLV
modules a year to the printing industry, doesn't know
when GLV displays will reach the market. And Sony isn't saying.
Sony did, however, offer a tantalizing demo of a
GLV-based projection television at a recent Combined
Exhibition of Advanced Technologies (CEATEC Japan), a
trade show held outside of Tokyo.
The colors were awesomely bright and vivid. During a
viewing of the trailer for the movie Spider-Man, the red
of the hero's suit fairly throbbed; the blues of the sky
and water scenes, requisite for any high-definition TV
demo, were captivating.
I had to know more about it. "A prototype," said the
Sony spokesman manning the company's show booth. Those
words pretty much exhausted his English, and I don't
speak Japanese.
I moved on to look at blue-laser disc recorders. Turns
out that wasn't a completely wrong turn.
Blue lasers will be essential to a commercial GLV TV,
along with green and red lasers. (TV 101: a television
picture is made up of red, green, and blue dots.) But it
wasn't until I got home to Silicon Valley that I found
out what a GLV actually does. Each GLV television
contains three of these special semiconductor devices.
The light valve was originally developed at Stanford
University, in California, by electrical engineering
professor David M. Bloom, along with Raj Apte, Francisco
Sandejas, and Olav Solgaard. In 1994, Bloom and several
others founded Silicon Light Machines to develop and
commercialize the technology. The company, now wholly
owned by Cypress Semiconductor, licensed Stanford's
patents (and went on to receive 39 related patents, with
some 100 more pending). So that's where I went to check
it out, with Silicon Light's product marketing manager,
Robert Monteverde.
The GLV is an optical microelectromechanical systems
device made using a conventional CMOS fabrication
process in 0.6-micrometer technology, without any exotic
steps or materials. Each sticklike silicon chip has 1080
"elements." An element consists of six flexible silicon
nitride ribbons arranged in parallel like a tiny
Venetian blind [see figure, "Color Controller"]. The
ribbonseach a couple of hundred nanometers thick, 3.65
micrometers wide, 220 µm long, with a 0.6-µm gap between
themare coated in their center regions with a reflective
top layer of aluminum. They are attached to the top and
bottom of a silicon substrate, then pulled taut and
suspended over it, like guitar strings. A television
system uses three of the silicon "sticks," one each for
the red, green, and blue lasers [see "Laser TV"].
The ribbons control how much red, green, and blue
light reaches the viewing screen and thus the actual
color of a pixel there, the same way the three colors of
phosphors function in a CRT color set. The intensity of
each of the three colors that strike the screen depends
on the position of the ribbons when the laser light hits
them.
This signal, in turn, depends on the TV picture to be
reproduced. What's particularly unusual about the
approach is that the GLV does not scan a single line at
a time horizontally across the screen, as in
conventional TV. Rather, the GLV projects a vertical
line of 1080 pixels all at once and sweeps the line
across the screen to produce the TV frame. This is done
60 times a second.
When the power to a six-ribbon valve is off, each
ribbon is stretched flat and rests in the same plane.
They form a mirror that reflects light straight back to
its source; no color gets to the screen. A voltage
applied between the ribbon and the substrate creates an
electrostatic attraction that pulls the ribbon toward
the substrate.
When alternate ribbons are pulled down, a portion of
the light aimed at the ribbons diffractscreating a wave
front of greater or lesser intensity depending on the
positions of the ribbons; other light is reflected.
Increasing the voltage pulls the ribbons further down,
causing differing amounts of light to diffract and
reflectthink of cranking open that Venetian blind. It's
the amount of diffracted red, blue, and green light that
determines the color of a pixel on the screen. Each GLV
element is switching at about 115 kilohertz a second for
each of the 1080 pixels in the vertical stick.
The ribbons move a quarter wavelength at most (which,
for green light, for example, is about 130 nm) and never
make contact with the substrate. That, Monteverde says,
makes the system quite durable and very fast.
Next, an optical projection system containing a
Fourier filter collects the diffracted light and rejects
the reflected light. The collected light is sent on to a
projection lens and then to a scanning mirrora flat
oscillating mirror that directs the 1080 vertical
elements across the display a column at a time to
produce a two-megapixel image. (For simplicity, the
figure shows only one pixel, but all 1080 pixels pass
through the optics at the same time.)
Besides the GLV chip itself, a GLV projection TV
contains a number of other components, including a
processor that adjusts the video data that determines
the voltages applied to the chip so the colors can be
faithfully produced. In addition, because laser light
tends to speckle, the light is also processed through a
despeckling filter so it appears consistent in brightness.
The technology most similar to GLV is digital light
processing, currently making a big splash on the
television market. It also uses a microelectromechanical
systems device, in this case a chip with hinged mirrors
in a two-dimensional array that tilt toward and away
from a light sourceon and offcreating light or dark
pixels. The system uses a single strong white lamp, but
the light is put through a color wheel to filter it into
red, green, and blue. It's cheap but relatively
inefficient, and it can't produce images as sharp as
those of a GLV-projection television.
The GLV-projection display is sharp, but it costs a
lot at the moment. The GLV chip itself is not the reason
for the high cost. Rather, the issue is the laser
diodes, in particular the blue and green. In fact, the
GLV was conceived before a blue laser diode was
available at all, in anticipation of the technology. In
the original prototype, made about five years ago as a
proof of concept, the green laser is an
intercavity-doubled neodymium-doped yttrium vanadate
(Nd:YVO4) laser. It is a 1064-nm
laser, which is then frequency doubled to produce 532-nm
green light. The blue laser is also an
intercavity-doubled Nd:YVO4
laser, but it uses the 915-nm laser line, which is
frequency doubled to produce 457-nm blue light.
Commercial products would likely use gallium nitride
diodes, which came on the market in the late 1990s for
the blue. Prices of those diodes are still high, and the
brightness of the laser is not yet what it needs to be
for a projection display.
Manufacturers are finding applications outside of
projection displays for GLV chips, which will help
accelerate economies of scale. A prime opportunity is in
commercial printing. GLVs are illuminated with infrared
light to paint an image onto a resist-coated aluminum
plate of both pictures and text coming directly from a
computer publishing system. This plate, attached to a
press, is used to do the printing. Agfa-Gevaert NV, of
Mortsel, Belgium, and Dainippon Screen Manufacturing
Co., of Kyoto, Japan, are currently selling commercial
printers that use the technology. It may soon be used in
the manufacture of integrated circuits, printed circuit
boards, and other electronic components; Silicon Light
has demonstrated printing of micrometer-scale images.
And a team at the Massachusetts Institute of Technology,
in Cambridge, is incorporating the GLV device into its
maskless lithography system, which will print into the
submicrometer region.
Another application is in telecommunications, where
the GLV can act as a dynamic gain equalizer or as a
reconfigurable blocking filter. Both are types of
tunable spectral filters used in optical communications.
One GLV can take 1080 channels of communications and
adjust the output of each independently.
Meanwhile blue-laser-diode prices are falling rapidly,
so commercial display products may soon arrive, although
putting those products on the market is a decision for
Sony to make. This is a technology for very big screens,
intended for displays at least as large as the wall of
an average conference room. It will probably first go
into commercial theaters and the business market, for
conference rooms and corporate theaters, then trickle
down to your home theater just in time for you to
replace that big-screen television one more time.