System and Method for Increasing Image Quality in a Display System

Abstract

System and method for maximizing image quality by eliminating vias on a reflective surface. A preferred embodiment comprises depositing a first portion of a mirror surface over a support surface, applying a protective coating on the mirror surface, and then inverting the via. The preferred embodiment also comprises removing a portion of the inverted via and then depositing a second portion of the mirror surface. The remaining portion of the inverted via fills the via and provides a level surface for the depositing of the second portion of the mirror surface, reducing the amount of light scattered by the via.

1 - 17 . (canceled) 
   
   
       18 . A display system comprising:
 an array of light modulators optically coupled to a light source, the array of light modulators configured to create images by setting each light modulator in the array of light modulators into a state needed to properly display the image on a display plane, wherein each light modulator includes a mirror comprising
 a pad coupled to a hinge of the light modulator; 
 a first layer of the mirror coupled to the pad by an arm, the arm to allow the mirror to pivot about the hinge; 
 a second layer of the mirror, completely covering the first layer of the mirror and the arm; and 
   the display system further comprising
 a controller coupled to the array of light modulators, the controller configured to issue commands to control the operation of the array of light modulators. 
   
   
   
       19 . The display system of  claim 18 , wherein the first layer of the mirror and the arm are formed by depositing a mirror material over a form with a via, and wherein the mirror material lining a wall of the via becomes the arm. 
   
   
       20 . The display system of  claim 18 , wherein the array of light modulators is a digital micromirror device.