sxrd lcd panel factory

Sony’s super popular VPL VW285ES projector uses SXRD display technology. SXRD, which stands for silicon x-tal reflective display, is Sony’s take on liquid crystal on silicon display, more commonly known as LCoS.

As a refresher, LCoS, which has been on the market for several years now, is a hybrid of DLP and LCD display technologies. It’s basically constructed of a layer of liquid crystal sitting on top of a reflective surface. The light created by the lamp reflects off this surface, unless the liquid crystal twists to block it.

Since their debut, LCoS projects have been notoriously difficult to manufacture. Sony streamlined the process by producing their SXRD panels in their own dedicated manufacturing facilities.

Sony’s SXRD panels are just as advanced as LCoS, if not more so. The SXRD projectors use a vertically aligned nematic (VAN) liquid crystal that changes state with lightning-fast speed. This enables the microdisplay to run as fast as 200 frames per second, with very little image smear.

Liquid crystal displays - whether in a LCD or LCoS panel - have an inherent minuscule motion blur. To overcome this, Sony’s HW40ES SXRD projector has a high 240HZ refresh rate. Advanced settings like film projection mode and a built-in motion smoother make for ultra smooth movement.

SXRD means Silicon, X-tal Reflective Display. SXRD stands for Liquid crystal on silicon (LCoS) microdisplays and it’s the latest on liquid crystal technology.

A lineup of two types of liquid crystal devices - the reflective type SXRD™ and the transmissive type BrightEra™. The type can be selected to fit the application.

The SXRD utilizes SSS’s original fine pixel pitch technology, pixel flattening technology and inorganic alignment technology to achieve a compact size, high reflectivity and high contrast ratio performance.

SSS"s unique high image quality signal processing function maximizes the characteristics of SXRD/BrightEra. In addition to the keystone correction that is found on many general projectors, there is also a “geometric correction function” for correction to an undistorted image when the projection screen is curved, and an “edge blending function” to eliminate the feeling of joints when multiple projectors are used to create a single image. These functions make it possible to increase the freedom in the projector installation.

As an example, there are 2.07 million pixels (full HDTV: 1920H x 1080V) arranged on the 0.37-type SXRD, which has a rectangular shape with a 0.37 inch diagonal (and 16:9 display aspect ratio). The size of a single pixel is 4.25μm square and the pixels are arranged with extremely narrow gaps, with only around 0.2 μm between the pixels. This realizes a smooth image with no feeling of mesh like a screen door.

In general, on microdisplays for projectors, the narrower pixel pitch is, the more likely it is that light will leak to the pixel driving element and that the performance of the pixel driving element will be degradess, which can easily lead to deterioration of the image quality. However, on SXRD, the addition of a light shielding layer and the optimization of the pixel structure have greatly improved the light shielding characteristics. It is even possible to maintain the image quality performance when there is strong incident light.

Sony rear-projection liquid crystal microdisplay technology overviewLight produced by a high-intensity projection lamp enters the optical block and is split into three paths (one each for red, green, and blue) by a series of lenses, condensers, mirrors, filters, and/or beam splitters. Each color has an LCD assembly with polarizing filters and a liquid crystal microdisplay panel (approximately 1" across).On Sony"s "3LCD" models, the light istransmitted through each LCD panel, and, on their "SXRD"(Silicon X-tal Reflective Display) models, the light is reflected off each SXRD panel.Finally, the three separately colored images are combined with a special prism into the final full-color image, which is then projected/enlarged onto the back of the screen by a projection lens.

For a more detailed explanation of 3LCD-based optical block technology, design, and failure, see below. Foradditional technical details about SXRD optical block technology from Sony, see this SXRD white paper, which compares conventional transmissive LCD and digital light processing (DLP) with SXRDtechnology. Also, see this HowStuffWorks article.

The following annotated photo shows various parts on the optical block of a 2004 3LCD model KDF-55WF655 (note that the LCD panel cover has been removed):

Pictured below is the 132-watt XL-2200 lamp used in several 2004 and 2005 3LCD models, including the KDF-55WF655 and KDF-60WF655, but other lamps are similar:

The photo below shows the internal parts of a 2004 3LCD model KDF-60WF655 optical block (structurally identical to the KDF-55WF655) with the LCD panel/prism block assembly removed from the center (courtesy of AVS Forum member "tdma"):

The "blue" light, which includes the ultraviolet (UV) portion of the light spectrum, then passes through a UV absorption filter that removes some of the UV light. Finally, the blue light bounces off another mirror and through the blue channel condenser lens, an orange-colored blue input polarizer, and the blue LCD panel. The orange-colored blue input polarizer is the final step to produce pure blue polarized light. The non-blue and improperly polarized light, including high-energy UV, is absorbed by this filter, turning it into heat. This leads to degradation in the absence of sufficient cooling.

Meanwhile, the "yellow" light that passes straight through the blue dichroic mirror next hits the green dichroic mirror, which splits off the "green" light and redirects it through the green channel condenser lens, the yellow-colored "green input polarizing filter", and the green LCD panel. The remaining "red" light travels through a couple of relay lenses and bounces off a couple of additional mirrors, redirecting it through the red channel condenser lens, the blue-colored "red input polarizing filter", and the red LCD panel.

Below are two photos with the input polarizers in place, but with the LCD panel/prism block removed. This photo shows the orange-colored input polarizer for the blue light path on the left, and the yellow-colored input polarizer for the green light path to the right. Note the open slots beneath each of the input polarizers, and the additional slots closer to the center of the cavity that line up with the LCD panels, used for air cooling:

The following annotated photo shows the LCD panel/prism block, which inserts into the cavity bounded by the input polarizers shown in the above photos. The prism area is indicated by a dashed teal square. Note that the LCD panels and output polarizers are secured to the prism with a gap of several millimeters, and that there is also a gap between the input polarizers and the respective LCD panels:

The LCD panels block the appropriate amount of light in each of the three separate color channels, and the remaining light goes through the output polarizers (one for each color that is similar to the respective input polarizers) attached between the LCD panels and the prism block (not shown). Finally, the three colors are recombined with the prism and projected through the projection lens off a large mirror behind the display screen, and then onto the display screen. The LCD microdisplay panels measure 0.61", 0.73", 0.74", 0.87", or 1.35" across, depending on the model.

Note that, on Sony"s 3LCD models, the light is transmitted through each LCD panel as shown here. In contrast, on their SXRD models, the light is reflected off the panels, so the interior structure of the optical block, as well as some of the parts are different than shown here.

Parts in the blue light path, particularly the orange-colored input polarizer and the LCD panel itself, appear to become degraded more rapidly than those in the other light paths for reasons described later. Below are some examples. When degradation of parts in the blue light path leads to insufficient/improper polarization of the light (e.g., breakdown of polarizing layers in the filters or panel), stray blue light makes it through the liquid crystal panel and gets projected on the screen, giving rise to blue discolorations. When degradation of parts in the blue light path leads to improper blocking of light (e.g., scorching of the filters or panel), light from the green and red channels predominates to form a yellowish color in areas that should be white or lightly colored.

Degraded blue input polarizer from my 2004 3LCD model KDF-55WF655 (Steve Linke). Note the change in appearance from orange to cloudy white in a rectangular shape (the shape of the incoming beam of light), as well as the squarish oval in the middle:

Degraded blue input polarizer (slightly out-of-focus) from a 2004 3LCD model KDF-60WF655 (courtesy of "tdma" of AVS Forum). Note the similarity in the degradation pattern to the closely related model above:

High-pressure mercury vapor lamps produce visible light with peaks in the red, green, and blue-violet ranges. However, they also produce large amounts of high-energy ultraviolet (UV) light, which gets filtered into the blue light path along with the blue-violet part of the spectrum. While some UV light likely is filtered out by the outer lamp bulb and UV filter(s) in the blue light path, a significant amount apparently remains unfiltered, as more effective UV filters remove too much of the visible blue-violet light. The polarizers and LCD panels are subject to degradation during prolonged exposure to UV and deep blue-violet visible light, at least in part due to the presence of organic dyes. Thus, the orange-colored input polarizer and the blue LCD panel tend to be the first to exhibit degradation. The blue output polarizer may also be subject to this damage, but to a far lesser degree.

The disadvantages of [3LCD] projectors include...Potential lifetime issues. [Liquid crystal] alignment layers used in [3LCD] light valves are organic polyimides (PIs). PI is susceptible to UV and deep blue light photochemical damage, which reduces operation lifetimes. UV filters with a long-wavelength cut-off are helpful, but tend to reduce the blue content of the final color imagery. The industry trend is toward UV filters with 50% transmission points between 430 and 435 nm...

Demerits [of SXRD] include...Lifetime. Long-term reliability of [SXRD] systems, as with [3LCD], is still a concern...Complexity. An [SXRD] optical system is more complex than either DLP or [3LCD] systems. Accurate control of the state of polarization is key to making [SXRD] products commercially competitive...

As the intense visible light is filtered by the polarizers and LCD panels, the blocked light can be converted to heat. This conversion is likely most intense in the high-energy blue light path.

The high-intensity projection lamp is directly adjacent to the optical block, and it creates a lot of direct heat. The filters and LCD panels may also be subject to degradation from this direct heat.

The following photo shows theinside case of my 2004 3LCD model KDF-55WF655 under the display area. The optical block inserts to the left, and the lamp portion sits on the right. The metal area by "lamp access" is where the lamp assembly can be accessed from the front of the TV for lamp replacement. Note the scorch marks on the plastic case where the lamp shines through its grid-shaped housing, which likely arises from intense heat and/or exposure to UV light escaping from the lamp.

As further evidence of the heat level generated by the mercury-vapor arc lamps, the WE610, WE620, WE655, and XBR950 models (2003-2004 3LCDs) have a documented issue in which parts adjacent to the lamps (100 or 120 watts, depending on the model) become warped, cracked, and/or scorched. Sony has extended the warranty on these models for this type of damage. The following photo is an example of the interior of a KF-42WE610 adjacent to the lamp (photo courtesy of AVS Forum member "Dayclone"):

The optical blocks are not sealed--at least in the 2003-2004 3LCD models. There is an air intake filter leading to the fan on the bottom of the optical block that cools the parts by directing air up through slots, but the filter is constructed of a material that can only exclude very large particles. In many cases, this fan becomes clogged with dust, which it then also circulates throughout the optical block. In addition, the top of the optical block is exposed with only an angled piece of plastic positioned over the LCD panels with open sides. Thus, dust can accumulate on the internal parts, which can further reduce cooling efficiency, as well as directly cause visual anomalies.

On the 3LCD models, there is a small centrifugal "lamp cooling fan" mounted to the top-left of the optical block (as you face the TV). This fan draws unfiltered air from inside the TV and blows it directly across the face of the lamp from top to bottom through perforations in the lamp housing. As the air comes out the bottom, it is directed out the back by another larger fan near the back of the TV. Interestingly, the air input to the fan is not far from the path of the outgoing air heated by the lamp, which could affect cooling efficiency.

In addition, there is a somewhat larger centrifugal "optical block cooling fan" mounted inside the optical block on the bottom-right (as you face the TV). This fan draws air from the void behind the projection screen through a crude filter and blows it up through multiple small ports beneath various parts in the light path--the main condenser lens/fly"s eye array near the beginning and the polarizers and LCD panels for each of the three color paths. The heated air presumably exits through the top of the optical block and out the sides of the open angled cover. There is an extra port above the condenser lens/fly"s eye array that directs air from these parts into the area of the angled cover.

Picture quality longevity studies commissioned by DLP competitor Texas Instruments have been conducted on liquid crystal projectors and TVs at the Rochester Institute of Technology"s Munsell Color Science Laboratory and an independent testing organization called Intertek. Studies on 3LCD models were conducted on front projectors, and the manufacturer(s) of the tested models were not revealed, but they are likely from Epson and/or Sony, the two main members of the 3LCD Group. Studies on SXRDTM models were conducted directly on Sony TVs.

The Munsell Color Science Laboratory conducted a preliminary study on five 3LCD projectors. The study commenced in May of 2002 on models that were popular at the time, and the results were reported in March of 2003. All five projectors showed early degradation of the blue channel (within 2,500 hours of usage), manifesting as blue or yellow discolorations, with eventual signs of degradation in the red and green channels. A theory was presented that organic compounds in the blue polarizers and LCD panels degraded during exposure to high frequency blue and UV light, causing the projectors to be unsuitable for use long before the end of their expected life spans.

The following slide from the preliminary 3LCD projector study shows examples of the blue and yellow discolorations developing over time (left to right):

Manufacturers recognize that the organic compounds in LCD panels and polarizers are susceptible to high heat and light energy stress, and will eventually break down if deployed in high stress environments...

This article on ExtremeTech (April, 2003) also presents additional details of the preliminary study. They interviewed a representative named Bob Getner from NEC, another 3LCD projector manufacturer, and described his comments as follows:

[Getner] claimed LCD projectors can be made for long life use, especially when designers focus on proper cooling. NEC designs its projectors to keep the insides as cool as possible to avoid detrimental effects. Getner was aware of the blue LCD problem and said NEC"s blue panels have a U/V filter to help protect against harmful light energy. Getner claims LCD projector design and lifespan is a function of engineering for expected usages.

Although the study was done on front projectors, the results were very consistent with observations of LCD panel and polarizer degradation in Sony"s 3LCD TVs correlating with blue and yellow discolorations, except that the longevity of the TVs tends to be modestly higher.

Follow-up 3LCD projector study (Intertek)The preliminary 3LCD study described above was criticized for using an unusually harsh duty cycle (continuous operation),  testing too few units (five), and not properly controlling environmental temperatures (77-85 degrees Fahrenheit ambient). So, Intertek conducted a follow-up study in 2005 to address these criticisms by testing three different duty cycles (continuous, 5.5 hr on/2.5 hr off, and 1.5 hr on/2.5 hr off) in triplicate on three LCD models (27 total units) at a constant ambient temperature of 75 degrees Fahrenheit.

The results of this study through December 2, 2005 are published in another Texas Instruments "white paper". In particular, see the Summary on page 6 and the Conclusion on page 61. Similar to the preliminary 3LCD projector study (above), initial signs of degradation (blue and/or yellow discolorations) arose between about 1,700 and 3,000 hours, with significant deterioration between about 2,000 and 4,000 hours in all units that reached those usage levels. The following statement appears in the Conclusion:

All of the LCD models in this study that have reached a certain number of on time hours have shown visual and measurable deterioration in display characteristics. Although the exact amount of time before deterioration varies, it generally appears to fall within the 2000 to 4000 hours of on time operation. This change appears to be related to the blue LCD panel and the blue and green polarizer.

The following images are extracted from the white paper on the follow-up 3LCD study, showing examples of blue and yellow discolorations developing over time (left to right), as well as degradation of the LCD panels and polarizers over time (click on the images for larger versions or view the original white paper):

Projector Central also has an article that included references to this follow-up study. In particular, see the "Weaknesses and Limitations of LCD" section, which includes the following:

Given enough prolonged exposure to high intensity UV light and extreme heat, the organic compounds used in most LCD panels are expected to degrade over long periods of time. This degradation can lead to a discoloration of the image and a reduction in contrast. The only way to fix it is to replace the damaged LCD panel, which is typically a cost-prohibitive proposition. You are normally better off buying a new projector.

The big question of course is how long the panels will last. There is no good data on this subject that has been compiled by an independent lab and published for general consumption. LCD vendors do not typically acknowledge LCD degradation can occur, so they don"t make any representations about expected life. In general, most LCD vendors maintain that to the degree LCD panels might be subject to eventual degradation, it will be beyond the practical life of the product.One trusted and very experienced industry source who develops products using both LCD and DLP technology believes that LCD panels have a lifespan in the range of 4,000 to 10,000 hours, with the lifespan depending on how bright the projector is--the brightest LCD light cannons will produce the most stress on the panels resulting in quicker degradation. Low brightness models such as those made for home theater will produce the least stress, and are expected to last longer.

Again, although this follow-up study was done on front projectors, the results were very consistent with observations of LCD panel and polarizer degradation in Sony"s 3LCD TVs correlating with blue and yellow discolorations, except that the longevity of the TVs tends to be modestly higher.

Sony SXRDTM rear-projection TV study (Intertek)Intertek also conducted a longevity study between March and October of 2006on seven Sony KDS-R50XBR1 SXRD rear-projection models purchased on the open market. They used three different duty cycles: one was left on continuously, three were 9.5 hr on/2.5 hr off, and three were 3.5 hr on/2.5 hr off. The "Results and General Summary" contained the following statement:

All the tested SXRDTM televisions developed a yellowing of the displayed image under 2000 hours of on time, usually in the top right or bottom right corner, which tended to spread across the screen.

Similar to the 3LCD models, Intertek determined that the yellowing of the displayed image arose due to a problem with the blue channel. These observations were all consistent with problems customers were experiencing during this same time period, right down to the location on the right side of the screen.

Interestingly, these observations also were later confirmed by Sony during discovery for the XBR1 class action lawsuit. In the judge"s Opinion and Order approving the settlement of that case, it was revealed that Sony acknowledged the yellow stain issue and claimed that it was caused by a "microscopic material" in the liquid crystal panels, disrupting their uniformity over time during prolonged exposure to UV light produced by the projection lamp. This was consistent with the problem in the blue channel observed by Intertek.

Sony also acknowledged that the issue typically started at the edge of the screen and enlarged over time, exactly as observed by Intertek. Sony claimed that the extent of the discoloration depended on the amount of microscopic material present in the panel, which varied from TV to TV, and the frequency of usage by the consumer. They also claimed that service records indicated that the issue always appeared within the first 3,000 hours of usage, if it was going to happen. They went on to claim that, between 1/2006 and 10/2006, they worked to reduce both the amount of the microscopic material and the amount of UV light exposure, and that, by 10/2006, they were producing non-defective optical blocks for the 2005 SXRD TVs.

Sony threat of legal actionMr. Ronald Wasinger, a Sony Vice-President in their Law Department, wrote a letter to Texas Instruments at the conclusion of the Intertek study (in 10/2006) threatening them with legal action if they distributed the Intertek SXRDTM study to the press or for marketing. Ironically, Mr. Wasinger suggested that the Study contained false and misleading claims in violation of federal and state deceptive trade practices and consumer protection laws. Here is an excerpt from that letter:

...Sony Electronics Inc. hereby demands that Texas Instruments immediately discontinue [sic] all distribution of the Study and cease making any claims in advertising, retailer training, or other communications that involve or relate...to...claims that SXRDTM televisions suffer or will suffer from yellow or other color non-uniformities...In striking contrast to the Study"s purported results, Sony"s own customer service data among thousands of satisfied consumers who purchased SXRDTM televisions in 2005-2006 indicate a service rate that is similar to or below Sony"s historical television averages...

...Texas Instrument"s [sic] subversive strategy with regard to SXRDTM televisions is eerily similar to the misleading comparative aging testing your company has distributed and used disparaging Epson LCD projectors and image degradation last year. Such marketing tactics demonstrate a pattern of unfair practices in the area of comparative advertising which we are confident courts and/or government regulators would determine to be unlawful.

US Patent 6,132,049 (priority date 9/16/1997): "Picture display apparatus and cooling apparatus for optical apparatus" (the liquid crystal panel and polarizer in the blue light path are particularly susceptible to damage when the high-energy blue light is converted to heat).

...[In the presence of intense/polarized light, the] optical components such as the [liquid crystal panel] and the polarizing plate are heated to a high temperature and the properties thereof are degraded. To be specific, the [liquid crystal panel] may cause a change of colors when heated to 70 degrees C or above...The polarizing plate may lose its polarizing function and not operate properly when heated to 80 degrees C or above...Such property degradation often results since the [liquid crystal panel] that transmits blue light has a high light energy absorption factor and tends to be heated to a high temperature...The life of the optical components such as the [liquid crystal panel] and the polarizing plate is reduced when used under a high temperature...and replacement [is expensive and inconvenient]...It is therefore preferable to increase the cooling efficiency of the [blue channel] liquid crystal panel and polarizing plate compared to the [red and green channel liquid crystal panels] and polarizing plates...

US Patent 5,757,443 (priority date 10/13/1995): "Transmission-type display device with a heat-dissipating glass plate external to at least one liquid crystal substrate" (heat radiating from the light source and intense light cause the liquid crystal in the liquid crystal panels to overheat and deteriorate).

The thickness of the liquid crystal panel, about 2 mm, is comparatively thin. As a result, when there are irregularities in the intensity distribution of the light from the light source, so-called hot spots occur because light becomes locally concentrated on the liquid-crystal panel and portions of the liquid crystal panel become heated. The transmittance of these hot spots differs from that of the surrounding portions, the enlarged and projected image becomes uneven and the quality of the appearance of the image therefore deteriorates. Further, radiation heat from the light source raises the temperature of the liquid-crystal panel and this is accompanied by deterioration in the characteristics of the liquid-crystal. As a result of this deterioration, display functions cannot be achieved with liquid crystal panels because liquid crystal panels used with projectors are heated to high temperatures using a powerful light source.

…[T]o keep off the heat generated from the liquid panels, cooling fans…are usually provided to blow airs to thereby cool the crystal panels…[H]owever, the liquid crystal panels are separately arranged from other optical components and the surfaces thereof come into contact with the air of low heat conductivity. Due to this, the cooling effect of the cooling fans [is] lowered, which adversely affects image quality. To improve the cooling effect, it is necessary to increase the rotation rate of the cooling fans…[H]owever, noises are produced unnecessarily by the cooling fans themselves as well as the blow from the fans...Owing to this, contaminants such as dust and dirt are easily attached to the incidence surfaces…, thereby resulting in a deterioration in image quality and a decrease in light quantity. In addition, the lights reflected on the incidence surfaces…become stray lights to thereby

US Patent 7,123,334 (priority date 12/4/2001): "Liquid crystal display device and liquid crystal projector device"(organic compounds in optical block parts, such as the liquid crystal panels and polarizing plates exhibit deterioration of reliability due to exposure to intense light and heat).

...[E]ach liquid crystal light valve [panel] generates heat owing to absorption of light or the like. Therefore, the temperature at the time of operation...increases. On the other hand, in the liquid crystal light valve, organic matter is used for not only the liquid crystal itself but also an orientation layer, a seal portion, a polarizing plate, a phase difference plate and the like. In addition, organic matter is also used for a flattening film and the like on a thin film transistor (TFT). Therefore, there has been worry about deterioration of reliability owing to increasing temperature or increasing quantity of light.

US Patent 7,535,543 (priority date 12/15/2004): "Liquid crystal display apparatus and cooling device" (light absorbed by optical block parts, such as the liquid crystal panels, heats them up, leading to deteriorated performance and shortened lifetime).

When the…liquid crystal display apparatus projects the image on the screen, most of the light emitted from the light source, not applied to the image projected and displayed on the screen, is absorbed into each of configuration members of the liquid crystal display apparatus such as the liquid crystal panel to generate heat thereof…[The] temperature range capable of realizing appropriate functions is limited. For example, when the temperature of the liquid crystal panel is higher than the rated temperature range, characteristics of a liquid crystal layer in the liquid crystal panel may change or air bubbles may be generated in the liquid crystal layer. And the displayed image quality may deteriorate. Otherwise, when the liquid crystal panel is retained for a long time at the temperature other than the rated temperature, the performance thereof may deteriorate, and a lifetime of the apparatus may be shortened. Therefore, the projection type liquid crystal display apparatus in which large intensity light is emitted to the liquid crystal panel is provided with a cooling device for cooling the liquid crystal panel.

US Patent 7,666,325 (priority date 9/29/2005): "Liquid crystal orientation layer and liquid crystal display element"(ultraviolet light deteriorates the orientation layers in liquid crystal panels).

Many other posted pictures of the problem show an uneven hazy border of blue at the bottom or other edges of the screen. Others show bright blue blobs that tend to be in the corners. See the eCoustics Sony Projection LCD TV Problems message board thread for many more examples.

Picture 1. "Front" view of the entire optical block. The optical block is in the center bottom of the TV case near the front. If you could see through the front of your TV, this is what you would see (the lamp housing is accessible through a door on the front of the TV). There is a centrifugal fan under the "fan housing" on the upper left that has a port that leads to the lamp area in the front-left. There is another centrifugal fan on the lower right (behind and below the cylindrical plastic protrusion with the white air filter around its perimeter that is just to the right of the projection lens). This fan appears to blow air up through LCD panel and lens/mirror areas. There is a black metal "LCD panel cover" that covers the innards, but it is open on the sides, so dust can move freely into it.

Picture 2. Left view of the optical block. The open side of the black "LCD panel cover" can be seen here, which opens near the "LCD fan port". The other side of the LCD panel cover is also open.

Picture 3. Top view of optical block with the LCD panel cover removed. The ribbon cables leading to the three LCD panels (blue, green, and red) are now visible.

Picture 6 (KDF-55XS955). Optical block with the lamp housing (on the left), the LCD panel cover and housing (on top), and the LCD panel/prism/projection lens/air filter module (on the right) removed. Note that the centrifugal fan on the lower-right is now visible.

Picture 7(KDF-55XS955). LCD panel/prism/projection lens/air filter module that was removed from the optical block (see Picture 6). Note that the blue LCD panel has been removed from its holder.

Picture 10. Fan removed from optical block. Note the dust build-up in the fins. There were also dust balls accumulated under the lamp housing. Presumably, the fan blows out the "lamp fan port" built into the housing directly onto the lamp to cool it. There are perforations at the top and bottom of the lamp itself that are aligned with the port, presumably to enhance cooling.The other centrifugal fan on the other side of the optical block presumably cools the LCD panel and lens areas by blowing air up through them.Also note that there are two other, larger fans in at least some models. On the KDF-55WF655, one is oriented horizontally straight back from the lamp, directing air out the back of the TV. This fan presumably clears hot air coming off the lamp. The other fan is on the far right as you face the TV, oriented vertically over the chassis unit that contains all of the audio and video connections (left side when facing the back). The air seems to be deflected off the case and out the back of the TV by this fan.

Picture 11. LCD fan port from the LCD side. This shows the "LCD fan port" opening on the side of the housing that contains the LCD innards. This opening leads to a lens area adjacent to the lamp. This may serve as an outlet for cooling air from the optical block fan that blows up from underneath the lenses. It empties into the same area (under the LCD panel cover) as the other cooling air that blows up across the LCD panels and filters. The effectiveness of this cooling system is questionable. It is also a concern that the whole thing is open to dust.

But not so fast. Sony has just introduced three new native 4K home theater projectors, the lamp-based VPL-VW715ES ($9,999 and the replacement for last year"s VPL-VW695ES, available in black or white), the laser-driven VPL-VW915ES ($19,999, available in black only), and the VPL-GTZ380 (available this winter). The latter"s price is TBD, but at over 100 lbs. with brand new SXRD panels, a new laser light source, and a rated 10,000 lumens of brightness, it"s Sony"s premier home theater projector and will likely command enough to equip six to eight rooms in your manse with their own VPL-VW715ES.

As I write this there"s as yet no announcement yet of a replacement for the VPL-VW295ES—Sony"s entry-level 4K projector— but the VPL-VW715ES, the subject of this review, likely has a few well-healed enthusiasts reaching for their platinum credit cards. Its SXRD panels (SXRD is Sony-speak for LCoS) are the same imagers used in its predecessor VPL-VW695ES. What"s new, however, is that the VW715ES incorporates an X1 main microprocessor, a projector-centric cousin to the powerful X1 processor used in Sony"s premier flat-screen sets. A Dynamic HDR Enhancer feature is said to make use of this increased processing power to analyze sources "scene-by-scene to deliver the best contrast performance when viewing HDR content." The idea of analyzing HDR content on the fly to optimize the tone-mapping is a good idea in principle given the brightness differences among HDR movies that would otherwise send you back to the menus to make adjustments on every title, and one that"s being implemented with varying degree of success by a couple of projector manufacturers to date. Given the penchant of all manufacturers to create unique names to differentiate their features from those of the competition it isn"t clear how Sony"s approach might be similar or different. What is clear is that the Dynamic HDR Enhancer definitely affects the projector"s PQ curve in a positive way (PQ, in general terms, is gamma for HDR). More on this a bit further on.

There are 10 available Gamma Correction settings for SDR (standard dynamic range) content. Sony"s Panel Alignment feature is also included, offering full convergence of the dedicated red, green, and blue imagers across the entire screen. I didn"t feel the need to use it with my sample, but it"s there for those who do.

The VW715 isn"t a terribly bright projector and is really intended for dark room viewing. Although you can get a decent image in moderate ambient light, it"s great strength -- the excellent black levels and contrast delivered by its LCoS-based SXRD imagers -- is largely lost once you have ambient light washing on the screen. It doesn"t make sense to pay this much for a projector and not get the key benefit you"re paying for (along with superb color accuracy and detail...which you CAN find in other projectors.

The VPL-VW325ES is Sony"s new replacement for the VPL-VW295ES, which in turn replaced the VPL-VW285ES back in October 2018 as the company"s least expensive native 4K SXRD projector. After holding both prior models to $4,999, Sony has raised the price of the VW325ES to $5,499. And thus marks the formal end to Sony"s long-running claim of offering "4K under $5K." I guess nothing is forever.

Also still missing in this upgrade of the VW295ES is any kind of dynamic iris that might help deepen the blacks. That can also be found in—you guessed it—the VW715ES. Still, the VW325ES at least starts with the excellent native black level of Sony"s 0.75-inch LCoS-based SXRD panels. Having a trio of them—one for each primary color—allows the 325ES to fully dodge two troublesome issues common to single-chip DLP projectors: unequal white and color brightness, and rainbow artifacts. Another benefit of LCoS imagers generally is the high "fill factor" that comes from requiring little space between the pixels. With LCoS, all the electrical leads for addressing the pixels are behind the reflective layer at the back of the chip. So the pixels on this projector are vanishingly small and the grid between them virtually undetectable with a 100 inch image, even with your nose at the screen.

With so much directly carried over from the VW295ES—including its most obvious omissions—you might be wondering what you get for your extra $500 when you step up to the VW325ES. The answer starts with inclusion of Sony"s new "X1 for projector" processor family that has resulted in recent updates to nearly every model in Sony"s pre-existing home theater line-up (the exception so far being the former flagship, the 5,000-lumen VPL-VW5000ES). The X1 Ultimate for projector processor is the most powerful and is found currently only on the VPL-GTZ380, while the others have the X1 for projector chip. Both are optimized versions of the X1 processor used in Sony"s best panel TVs. Across all the new models, the extra speed and brain power enable two key new or updated features: Dynamic HDR Enhancer and Super Resolution Reality Creation.

For background, I"ll first repeat what we"ve previously reported in reviews and in this comprehensive article on HDR about the challenges of reproducing HDR on a projector. HDR video, and specifically the HDR10 format we"ve seen employed for most content, was designed with flatpanels in mind that are capable of peak highlights that hit close to 1,000 nits or more. By contrast, home theater projectors typically top out around 150 nits, sometimes closer to 100 nits depending on the lumen specification.

With some HDR content being mastered today with peaks of 4,000 nits or greater (and with a theoretical maximum of 10,000 nits for HDR10), today"s consumer panel TVs and projectors must all perform "tone-mapping" to adapt the brightest highlights and deepest blacks to the capabilities of the display. The best TVs have self-emissive pixels (as with OLEDs) or multizone local-dimming backlights (as with LED-driven LCD sets) to allow the TV to simultaneously darken specific pixels or zones while pumping up the brightness on others. This makes them well-suited to HDR.

Moving on to other features: the side connection panel on the VW325ES mimics that of the VW295ES it replaces; it is modest but sufficient for most applications. The pair of HDMI ports are version 2.0b, not the latest HDMI 2.1 ports that could potentially support 4K gaming at 120 Hz from the newest game consoles. It"s another disappointment to see a new generation of projectors from Sony that doesn"t have HDMI 2.1. But this model does carry over from the VW295ES the Input Lag Reduction switch in the menu that cuts input lag from a rated 80 ms to approximately 27 ms with 4K 60Hz signals. That"s not exactly gaming projector territory but is far better than most projectors. Unfortunately, I couldn"t fully verify this spec because our Bodnar 4K lag meter wouldn"t sync with the projector when putting out 4K/60 signals (I had the same problem with the VW295ES). But we got 36.2 ms with 1080p/60. The Input Lag Reduction function is available for any preset picture mode and has essentially the same effect, though it is only on by default in the Game mode.

Contrast and the overall dimensionality of the image were also really outstanding thanks to the deep native black of the SXRD imagers. A big part of the allure of this projector is that things pop so well off the black floor, even if the letterbox bars don"t exactly disappear into the velvet frame on my screen. In particular, typical mixed scenes with both dark and bright elements really had an amazing sense of depth and dimensionality.

Jeff, I was very impressed with the contrast and black levels on this projector despite lack of an iris. I do believe that Sony"s latest SXRD chips are very likely far superior in this regard to what"s in your HW15.

Matt, two things to put in perspective here. One is that Tom is a bit more stringent than I am in wanting things to measure right and there was no way to get the 715 to look the way he wanted on the HDR EOTF curve in Calman. I initially agreed with him when I began watching HDR on the 325 that Sony"s HDR tends to look dark and bury the shadows, but I was perfectly happy to move to one of the slightly less color accurate brighter modes and adjust by eye to get a result I liked. HDR is one of those things with projectors that just doesn"t calibrate easily, especially with Calman software designed for flatpanels,and I have almost given up on using it for HDR beyond a bit of tuning to get RGB in balance on the grayscale and reasonably close to whatever color temperature you"re targeting. At this point, I believe my HDR assessment of a projector should be based on whatever image the manufacturer provides out of the box and whatever else I can do (mostly by eye) to make it look satisfying to me.

Thanks for that thought, Sean. I admit my 92 is a bit small by most standards. I expect to upgrade to a 100 inch soon in a similar 1.3 matte white gain, but I do feel that this is a very common screen size and the starting point for most folks in making a decision to go with a projector vs. a big panel display. We have a 110 inch in our studio, which is a little bigger and right in that 100-120inch range I think a majority of users probably fall into. It"s also a reasonable size for typical 4K home theater projectors today to be able to drive to decent brightness for HDR and perhaps moderate ambient-light viewing of sports or news. But I"m glad you"ve gotten satisfying performance from your 45ES, which is a great 1080p projector.

Thanks Rob, you helped make the decision to go with the WV325 when I was at the store to see the 5050 (which also impressed). This article was posted while I was there. As we sit 8 feet or less from a 130" screen, I worried about seeing the pixels with LCD. This thing is incredible with none and the picture just pops. I saved and waited years to replace an old Panasonic PT-M1083 CRT (no pixels and 1080) that had great blacks. This is lots brighter than that, even in low lamp mode. I wouldn"t fear the brightness if using in a totally dark room.

Hi Rob, Great review. I am definitely considering replacing my Epson 6040 with the VW325ES. This will be my first Sony projector and I have read in various forums that there is an issue with all Sony projectors having degradation problems with their SXRD panels. Have you heard of this and/or should it be of material concern? Thanks!

Years ago Sony"s early SXRD rear projection models (and pesumably their earlier SXRD projectors) had some issues with this, but I don"t know about the current generation models that mostly use the same late-gen SXRD chips. I think information found on the forums can usually be deemed accurate but not necessarily as widespread as it might seem to be based on a few periodic posts as opposed to a legion of people complaining about any given problem

I"m trying to decide whether to plunge into a new projector like this one, or suck it up and grab a similarly priced 77" OLED Bravia. Based on what I"ve read, the OLED panels can produce a "better" image, but (in my opinion) they kinda lack the whole "theater" experience you get with a projector.

Is there even such a thing as an OLED projector? You"d think if they can make a native 4K OLED cell phone, they could pack panels into a projector... but what do I know.

I"d recommend this excellent projector to replace your old projector over an OLED panel. Size matters, as does the unfatiguing quality of a projected image.

The VPL-GTZ380 utilizes Sony’s highly regarded 4K SXRD panel technology to deliver crisp imagery. It has a rated brightness of 10,000 Lumens with a native contrast ratio of 16,000:1 along with 100% DCI-P3 color reproduction and HDR Support.

The GTZ-380 can be used in a wide range of corporate, entertainment, and simulation applications. The VPL-GTZ380 features a newly developed 0.74” Native 4K SXRD panel which is Sony’s proprietary version of LCoS technology to deliver 16,000:1 contrast ratio and deep blacks. Adopting a new liquid crystal material for the panel dramatically improves light stability and durability while producing a rated 10,000 lumens of brightness.

“In a few short years, our SXRD lineup of 4K projectors have become the industry standard with installations at influential customer sites across the world,”said Theresa Alesso, pro division president, Sony Electronics. “The newest addition to the family, the VPL-GTZ380, excels in dark and bright environments and is a direct result of insights we’ve gathered from key clients in training and simulation, as well as at entertainment venues, corporations, museums and planetariums. We’re proud to have developed a new solution that not only exceeds their requirements but fosters users’ creativity allowing them to bring their vision to life with unparalleled image expression.”

To further enhance picture quality the GTZ380 is the first Sony projector to utilize the new picture processor called “X1 Ultimate for projector” which is based on the original X1 Ultimate processor used for Sony’s high-end line of BRAVIA TVs. While the processor was originally designed for Sony’s lineup of OLED and LCD flat panel TVs, this version has been optimized for projectors with the goal of enhancing the picture quality of projected images.

At only 112 pounds, the VPL-GTZ380 is lightest and most compact native 4K projector in its class. This has a lot to do with the SXRD Panels used in GTZ Series projectors. The SXRD panels have a pixel density of about 61,000 pixels per square mm which is a much higher density than those found in competing DLP and transmissive LCD projectors.

The SXRD panels utilized in the VPL-GTZ380 are not significantly smaller and denser than a comparable 4K DLP chip, they can deliver much a higher native contrast ratio of 16,000.1. A smaller, denser SXRD panel also reduce the size of the optical block and lenses, resulting in a compact projector which can deliver the performance of a large model.

For cooler operation, the phosphor wheel features a patented spiral fin which provides more efficient heat dissipation. Its liquid SXRD panel cooling system and streamlined air flow design makes the VPL-GTZ380 very quiet for such a bright professional projector at just 39dB.

LCOS is a reflective LCD display panel with high open area ratio. Basically, by placing the wiring area and switching elements under the reflection layer, there is no black matrix area - so it is possible to view a near-seamless image. LCOS systems can be created as 1 chip and 3 chip systems.

At the moment (meaning the next 15 minutes), LCOS technology is fairly competitive in terms of price and performance advantages compared to LCD and DLP systems. Pixels on LCOS panels can be made smaller than is possible with most other microdisplay technologies, without compromising picture quality or manufacturability. LCOS displays can be scaled to 1080i/p resolution (1920x1080 pixels) and beyond, without increasing the size and cost of the panel and other optical components in the light engine.

The future, we hope, now that manufacturer Syntax-Brillian has entered the picture and picked up where Intel dropped the ball. Better, faster, cheaper. LCOS technology is still relatively expensive compared to LCD and DLP, and with Intel opting out of mass production in 2004 that can be expected to remain for some time. This means that HDTVs based on LCOS technology may remain more expensive than the competition. Right now the main players are JVC, Philips, Sony and Syntax-Brillian (with a one-off from Mitsubishi and a couple front projection products from Canon) so we"ll have to look out to see how effectively they manufacture and market their products.

Despite a lot of hoopla, Sony Electronics actually seems to be driving this market single-handedly - at least as far as the consumer market is concerned. While companies like Brillian continue to post endless press releases of financials and new marketing initiatives (including the acquisition of Syntax Groups and the Olevia brand or LCD TVs) the name recognition is through SXRD and Sony.

Travis, I also have the SXRD 60 inch tv with the greenish tint (started about Jan/Feb ’14) After investigating online, looks like options to replace by Sony have expired. I got one $500 estimate to repair. Might get another estimate. Most likely I’ll be replacing the TV with an 60″ LED type. It’d be more current on technology (Wi-Fi, more HDMI outputs, Smart, etc).

I just hung up with Sony on trying to get information about a green hue I have on my SXRD TV. The support tech actually lied to me 6 times before I was able to get ‘Dennis’ to admit the truth. Dennis stated that Sony has never had an ‘Optical block’ problem, that there had never been a class action suit on this issue, that they have never offered any kind of replacement, and the the internet had lied about all of this. I asked to be moved to a higher level and he stated that when he would transfer me that it would go to someone else of his level with the same information. How can you trust a company that lies to you right from the beginning?

Went TV shopping a few days ago. Sales tried to sell me a Sony. I’ll never buy another Sony! He asked why and I told him about my SXRD 60 inch.Had it since 2007. It was ok for 2 years,then went yellow.We have put up with this ever since,plus 3 proj. bulbs. Then he tells me about the consessions Sony has offered. Am I the only person on earth that didn’t know this?

Made contact with Sony and was offered three poor options..7 days to accept. Three days later I was blocked from getting any more help on my issues with the defective 2008 55″ KDS 55a3000 SXRD. What to do? Sony never even told me of this product built to fail.

I just worked with Sony on my 55″ SXRD tv issue that included a yellow tint to the picture. The offer I got was for a 55KDL500 for $300 or a 46″ model for $25. I took the $300 55″. Shame though that the picture on the new LCD is not as clear as the SXRD when working well.

The optical block failed about 2 months ago on my 4 year old 60″ SXRD (KDS60A2000 – manufactured Sept. 2006 ). I just got off the phone with Sony…the offers are:

Have a KDS-R60XBR1 with optical block problem. Called Sony about two weeks ago. They provided an event # and asked that I provide a pic of the TV with the event number and the seriel number tag from the back of the tv. You must carefully remove it and tape it on the paper. I took a pic of the tv during a Ford commercial which has lots of white screen space which clearly shows the green halo. I’m now waiting for the 60EX700 LCD HDTV to be shipped ($325+tx). Thanks everyone for your posts.

I have a 60″ SXRD XBR2 that has been “Fixed” 2 times , how did you hear about this deal ? How can i get this deal ? I know the extended warranty runs out in a month of whatever .. i paid $4300 for poop basicly