Projector light source with longitude and latitude conical surface grid structure and tool clamp

Abstract

A projector light source with a longitude and latitude conical surface grid structure comprises an LED area array PCB, a longitude and latitude board conical surface grid assembly, a reflection coaming, a heat dissipation structure, a shell and the like. The core technical characteristics are that the LED area array PCB is covered with the longitude and latitude plate conical surface grid assembly; the warp and weft plate conical surface grid assembly comprises a warp plate and a weft plate, the warp plate and the weft plate are provided with inclined seams (notches) for mutual insertion, the inclined seams (notches) are characterized in that opposite inclined seams are formed in a group of splayed shapes, one end of each inclined seam is communicated to the boundary of the long edge of the warp plate and the long edge of the weft plate, and the warp plate and the weft plate are mutually interwoven and inserted to form a warp and weft conical surface grid structure. The rectangular pyramid surface is composed of multiple rectangular pyramid surfaces arranged vertically and horizontally; the tool for manufacturing the warp and weft plate conical surface grid assembly by using the warp plate or weft plate maintaining assembly is high in light source brightness, better in uniformity and lower in cost, and is widely applied to projector manufacturing of LCD light valves.

Description

[Technical Field]

[0001] This invention belongs to the field of optical-electronic technology; specifically, it is a light source that greatly increases the brightness of the optical engine of a projector (while maintaining high optical quality: such as optical extension; characterized collimation, etc.) and a tooling fixture for assembling the light source. [Background Technology]

[0002] The development of projectors has gone through three main stages: CRT projection technology, LCD projection technology, and the more recently developed DLP projection technology. The core of a projector includes three main parts: the projector structure, the optical engine (including the lens assembly), and the electrical control and interface. A crucial component of the optical engine is the light source.

[0003] LCD (Liquid Crystal Display) projectors: In recent years, LED light sources have been widely used in projectors. A single multi-core LED light source is covered with an aspherical lens, expanded and shaped, and then projected onto a light valve; this is widely used in small projectors. The light source for a single-chip color LCD projector is relatively simple. Specifically, dozens of white LED chips arranged together are converged by an aspherical lens and then shaped by a lens, or directly reflected by a funnel-shaped reflector before being projected onto the light valve display panel of the LCD, and then projected onto the screen by a lens assembly. However, both methods have significant shortcomings in efficiency, mainly because the scale of the multi-LED chip array is too large, making it difficult to efficiently shape a collimated beam with a certain scattering angle and quality.

[0004] Currently, the problems with single-chip color LCD projector light sources are: screen brightness uniformity and insufficient brightness. This is because the reflections from aspherical lenses and funnel-shaped reflectors are not uniform in spatial solid angle distribution. On the other hand, the light emission ratios of the center and corners of the projector lens assembly are different, with the center often having a higher light emission ratio. These two factors combined cause the problem of screen brightness uniformity, where the brightness at the center is often greater than that at the corners, and the brightness at the edges is greater than that at the corners. [Summary of the Invention]

[0005] The purpose of this invention is to address the shortcomings of existing technologies, solve the problems of screen brightness uniformity and insufficient brightness, and improve the efficiency and layout of the light source, arranging as many LED beads as possible within the allowable range of heat generation.

[0006] The present invention features the use of ingenious tooling to enable the assembly of the warp and weft plate conical grid assembly, thereby reducing costs and improving brightness and uniformity.

[0007] The content of this invention:

[0008] The projector light source structure of the latitude and longitude conical grid structure of the present invention includes:

[0009] The components include an LED array PCB board, a warp and weft conical grid assembly, a reflector enclosure, a heat dissipation structure, and a housing. The heat dissipation structure includes a heat sink, a shroud, and a fan. The fan's airflow passes through the shroud and blows directly onto the heat sink. The LED array PCB board is equipped with horizontally and vertically arranged LED beads. The warp and weft conical grid assembly includes warp and weft plates with diagonal slits (notches) for interlocking. The diagonal slits (notches) are characterized by a series of figure-eight-shaped diagonal slits. One end of the diagonal slit leads to the boundary of the long side of the warp and weft plates. The interlocking of the warp and weft plates forms the warp and weft conical grid structure, which is composed of numerous horizontally and vertically arranged quadrangular pyramidal surfaces. The small area of ​​the pyramidal surface is defined as the light inlet.

[0010] The installation relationships of the various components and parts are as follows:

[0011] The LED array PCB board is mounted on a heat dissipation structure (usually aluminum), and the LED beads on the PCB board are directly connected to the entrance array surface of the conical grid assembly. Each LED bead is located in the central area of ​​its respective entrance. The light emitted by each LED bead at various angles is continuously reflected by the inner surface of the conical grid. Due to the beam-expanding conical light guide relationship, the angle between the reflected light and the principal optical axis decreases with each reflection; the more reflections, the smaller the angle between the reflected light and the principal axis. Ultimately, the light from the LED beads is... The large opening of the conical grid of the warp and weft plate (the large quadrilateral exit surface, i.e. the base of the large truncated pyramid) projects out the light, greatly reducing the solid angle of the emitted light distribution and concentrating it in the direction of the main optical axis (perpendicular to the PCB board of the LED). The light emitted from the entire warp and weft conical grid structure is then limited and reflected by the barrel-shaped reflective enclosure, resulting in a uniform light field (beam) with a small divergence angle in the rectangular exit area of ​​the reflective enclosure. Finally, the light is coupled and incident on the LCD light valve display screen and transmitted out. The image is then projected onto the screen by the lens assembly to generate a projected image.

[0012] Uniformity analysis of emitted light:

[0013] Firstly, the solid angle of light emitted by each LED on the LED array PCB is quite large, generally ranging from 60 to 130 degrees. To reduce this solid angle, a micro-LED lens or a conical (inverted funnel-shaped) reflective surface can be used to cover each LED. However, lenses on the scale of a few millimeters are insufficient to achieve a small solid angle of light emission within 20 degrees. Regarding uniformity in the display: because light from all LEDs can only be received from a distance from the PCB of the LED array with a small solid angle, only a small number of LEDs can be received at close range, and the closer the distance, the fewer LEDs can receive light. Therefore, the LED array PCB and the LCD transmissive light valve need to maintain a suitable distance (the LCD transmissive light valve is located on the projection plane shown in the attached diagram). This distance satisfies the requirement that the area of ​​the light spot projected by a single LED onto the LCD transmissive light valve is between 1 / 40 and 1 / 5 of the total area of ​​the LCD transmissive light valve to achieve sufficient uniformity.

[0014] Compensation methods to overcome excessive brightness in the center of the projector (device selection):

[0015] In the center of the LED array PCB board, some low-brightness LED beads are set up to reduce the brightness of the central area. The specific PCB wiring method is as follows: insert low-brightness LED beads into a series LED circuit, and these low-brightness LED beads are distributed in the center of the LED array PCB board; or connect low-brightness LED beads in series and distribute them in the center of the LED array PCB board.

[0016] The core structure of the specialized tooling fixture for completing the conical grid assembly of the warp and weft plate includes:

[0017] The assembly consists of a warp (or weft) retaining component, an upper baffle, and a push plate. The basic installation relationship is as follows: the warp (or weft) retaining component and the upper baffle are held in relative position by retaining parts, and can be moved away when not needed to avoid obstruction. The warp (or weft) is inserted into the oblique notch of the retaining component, and fully inserted. The insertion depth of the warp (or weft) should be such that the oblique seam of the warp (or weft) is completely exposed outside the retaining component (usually from the top). Next, the wefts (or warp) are inserted one by one into the oblique seams of the warp (or weft) below. The insertion depth is limited by a limiting bar. The insertion depth is such that the long side of the upper weft plate (or warp plate) just touches the bottom of the diagonal seam of the lower warp plate (or weft plate), stopping it from falling further. The entrance distance of the slit at the corresponding boundary of the upper plate is equal to the distance at the bottom of the corresponding diagonal seam of the lower plate (this ensures that the upper and lower plates are properly aligned after insertion). After all the upper weft plates (or warp plates) are in place, the upper baffle is moved down to abut against the upper long side of the upper weft plate (or warp plate). Then, the push plate moves upward, passing through the hollow part of the retaining component, which pushes the lower warp plate (or weft plate) upward until the warp and weft plates are aligned as a single unit.

[0018] Technological advancements of this invention:

[0019] The conical grid structure and tooling of the warp and weft plate not only greatly reduce the overall cost, but also significantly increase the light efficiency; by setting some scattered low-brightness LED beads in the center of the LED array PCB board, the brightness uniformity of the projection is greatly improved.

[0020] [Illustration]

[0021] The present invention will be further described below with reference to a preferred embodiment;

[0022] [ Figure 1 Overall diagram of the projector light source with a latitude and longitude conical grid structure.

[0023] [ Figure 2 A disassembled schematic diagram of a projector light source with a latitude and longitude conical grid structure.

[0024] [ Figure 3 ]、[ Figure 4 Schematic diagram of the conical grid structure of the warp and weft plate.

[0025] [ Figure 5 ]、[ Figure 6 ]、[ Figure 7 Diagram showing the assembly of warp and weft plates and tooling fixtures.

[0026] Label Explanation:

[0027] (1) Conical grid structure of warp and weft plates

[0028] (1-2) Warp plate

[0029] (1-3) Weft plate

[0030] (1-4) Diagonal seam

[0031] (1-5) Oblique angle

[0032] (1-6) Funnel-shaped reflective unit

[0033] (1-7) Entrance

[0034] (2) LED array (PCB) board

[0035] (3) Reflective enclosure

[0036] (4) Heat dissipation structure

[0037] (4-1) Fairing

[0038] (4-2) Electric Fan

[0039] (4-3) Heat sink

[0040] (5) Arrow

[0041] (6) Main optical axis

[0042] (7) Reflected light

[0043] (8) LED beads

[0044] (9) Disassembly diagram

[0045] (10) Tooling and Fixtures

[0046] (10-1) Frame retaining assembly

[0047] (10-2) Gap

[0048] (10-3) Upper baffle

[0049] (10-4) Push plate

[0050] (10-5) Limit bar

[0051] (10-6) Spiraling

[0052] (11) Projection solid angle

[0053] [Implementation Case]

[0054] like[ Figure 1 ]、[ Figure 2 As shown:

[0055] The projector light source structure with a latitude and longitude conical grid includes: an LED array PCB board (2), a latitude and longitude conical grid assembly (1), a reflector enclosure (3), a heat dissipation structure (4), and a housing; the heat dissipation structure (4) includes: a heat sink (4-3), a shroud (4-1), and a fan (4-2), wherein the fan air passes through the shroud, or without the shroud, the fan blows directly onto the heat sink (4-3); the LED array PCB board (2) is equipped with longitudinally and transversely arranged LED beads (8); the structure of the latitude and longitude conical grid assembly (1) includes: Including: There are oblique slits (1-4) on the warp plate (1-2) and the weft plate (1-3) for interlocking. The angle between the oblique slit and the short side is called the oblique angle (1-5). The oblique slit (1-4) is characterized by a pair of figure-eight oblique slits. One end of the oblique slit leads to the boundary of the warp plate and the weft plate. The interlocking of the warp plate and the weft plate forms a conical grid structure, which is the inner reflection unit that constitutes many funnel-shaped reflection units (1-6). The angle between two warp plates or two weft plates is the oblique angle (1-5). When the oblique angle is equal to 0 degrees, the angle is zero degrees or they are parallel to each other.

[0056] The installation relationship of each component and part is as follows: the LED array PCB board (2) is installed on the heat dissipation structure (4), and the LED beads on the LED array PCB board (2) are directly connected to the entrance (1-7) array surface of the conical grid assembly (the small area surface of the conical surface is defined as the entrance). Each LED bead is located in the central area of ​​each entrance. In this way, the light emitted by each LED bead at each angle is continuously reflected by the inner surface of the conical grid of the warp and weft plate. Due to the light guide relationship of the beam expanding conical surface, the angle between the reflected light (7) and the main optical axis is reduced with each reflection. The more times the reflection occurs, the smaller the angle between the reflected light and the main axis becomes. Finally, L The light from the LED beads is projected out through the large opening of the conical grid of the warp and weft plates, and the solid angle of the outgoing light distribution is greatly reduced (the angle with the main optical axis is smaller; the original 120-degree light emission range of the LED can be concentrated into a 15-degree light emission range), and concentrated in the direction of the main optical axis (6), as shown by the LED projection solid angle (11); the light emission of the entire warp and weft conical grid structure is then limited and reflected by the square barrel-shaped reflective enclosure (3), and a uniform light field with a small divergence angle will be obtained in the rectangular exit area of ​​the reflective enclosure (3). Finally, it is coupled and incident on the LCD light valve display screen and transmitted out, and then the image is projected onto the screen by the lens group.

[0057] like[ Figure 3 ]、[ Figure 4 As shown:

[0058] The warp and weft plate conical grid structure (1) is composed of warp plate (1-2) and weft plate (1-3); on the warp plate (1-2) and weft plate (1-3), there are pairs of oblique slits (1-4); the included angle between adjacent oblique slits is oblique angle (1-5); the surface of the warp plate (1-2) and weft plate (1-3) is electroplated with a reflective layer; each conical grid structure corresponds to an entrance (1-7) (the small area end of the 4-sided pyramidal surface) and a light outlet (the large area end of the 4-sided pyramidal surface); the light emitted by the LED beads (8) on the LED array (PCB) board (2) passes through the entrance (1-7), is reflected multiple times by the 4-sided pyramidal surface, and is emitted from the light outlet, as shown by the reflected light (7); the main direction of the projection solid angle (11) of the emitted light is the direction of the main optical axis (6) (perpendicular to the direction of the LED array (PCB) board (2)).

[0059] like[ Figure 5 ]、[ Figure 6 ]、[ Figure 7 As shown:

[0060] [ Figure 6 The diagram framed by the dotted line at the bottom shows the state after the weft plate (1-3) has been removed as shown in the diagram above; the diagonal seams (1-4) are arranged in pairs in a figure-eight pattern, with the angle between the figures being a diagonal angle (1-5); on the two crossbeams of the weft plate retaining assembly (10-1) of the tooling fixture (10), there are oblique notches (10-2) that match the diagonal angle (1-5); the width of the notch (10-2) is slightly greater than the thickness of the warp and weft plates, just enough to insert the weft and warp plates; the state after the weft plate (1-3) is removed from the weft plate retaining assembly (10-1) is as shown in the disassembly diagram (9).

[0061] [ Figure 5The core structure of the special tooling fixture (10) for completing the warp and weft plate conical grid assembly includes: a weft plate retaining assembly (10-1), an upper baffle, and a push plate; its basic installation relationship is as follows: the weft plate retaining assembly (10-1) and the upper baffle (10-3) are held in relative position by retaining components, and can be moved away when not needed so as not to interfere with the weft plate. The weft plate is inserted into the inclined notch (10-2) of the weft plate retaining assembly (10-1) and fully inserted into place; then... Insert the warp slabs one by one into the beveled notch (10-2) of the weft slab retaining assembly (10-1) below; the insertion depth is limited by the top of the limiting bar (10-5) on the weft slab retaining assembly (10-1) to prevent the warp slabs from falling further. This insertion depth is such that the long side of the upper weft slab just touches the bottom of the lower warp slab (10-2), and the beveled seam of the upper weft slab is aligned with the bottom of the beveled seam of the lower warp slab; after all the upper weft slabs have been placed, the warp slabs need to be held in place. The insertion depth is just right to: expose the entire oblique seam of the warp plate; move the upper baffle to abut the upper long side of the upper weft plate (or warp plate); the elastic deformation capacity of the weft and warp plates can withstand certain processing errors; the push plate (10-4) moves upward, passing through the central area (lower opening) of the insertion weft plate retaining assembly (10-1), and the push plate (10-4) pushes the lower weft plate (1-3) upward together, so that the non-oblique seam position of the lower warp plate is aligned with the upper... After the oblique seam depth of the square warp plate is inserted into all the notches and fully matched and firmly inserted, the warp plate and weft plate are connected synchronously and integrally in one go; move the upper baffle (10-3) and push plate (10-4) along the direction of arrow (5); the upper baffle (10-3) stops moving when it touches the warp plate, while the push plate (10-4) continues to move upward after touching the weft plate; when the push plate (10-4) passes through the central area opening of the weft plate retaining component (10-1), the warp plate and weft plate are connected integrally in one go.

Claims

1. The basic structure of a projector light source with a latitude and longitude conical grid structure includes: The components include an LED array PCB board, a conical grid assembly, a reflector plate, a heat dissipation structure, and a housing. The heat dissipation structure includes heat sinks, a shroud, and a fan, or a fan directly blowing air onto the heat sinks. LED beads are arranged in a horizontal and vertical pattern on the LED array PCB board. The installation relationship of each component is as follows: the LED array PCB board is mounted on the heat dissipation structure, and the LED beads on the LED array PCB board are directly connected to the conical array inlet of the conical grid assembly, with each LED bead located in the central area of ​​the inlet. Thus, the light emitted by each LED bead from various angles is absorbed by the inner surface of the conical grid. Continuous reflection reduces the angle between each reflected ray and the principal optical axis, and the light projected through the large opening of the conical grid is concentrated along the principal optical axis. The light emitted from the entire conical grid structure is then confined and reflected by the barrel-shaped reflective plate, resulting in a uniform light field with a small divergence angle in the rectangular exit area of ​​the reflective plate. Finally, the light is coupled to the LCD light valve display screen at the exit of the reflective plate. The brightness of the LED beads arranged in the horizontal and vertical directions on the LED array PCB board can be either the same or different, which is used to select devices to compensate for the excessively high center brightness of the projector light. Its features are as follows: a warp and weft conical grid assembly is covered on the LED array PCB board, or a micro-LED lens is covered on each LED bead; the warp and weft conical grid assembly includes: warp plates and weft plates with oblique slits (notches) for interlocking, the oblique slits (notches) are characterized by a family of figure-eight-shaped oblique slits, one end of the oblique slit leads to the boundary of the long side of the warp and weft plates, the interlocking of the warp and weft plates forms the warp and weft conical grid structure, which is composed of many quadrangular pyramidal faces arranged in a longitudinal and transverse manner, and the small area of ​​the pyramidal face is defined as the light entrance; in the tooling for completing the fabrication of the warp and weft conical grid assembly, a warp or weft plate retaining assembly is used as a fixture to simultaneously fix the warp or weft plate: an oblique slit or notch is opened on the top of the retaining assembly to insert the warp or weft plate, the depth of the oblique slit or notch is just enough to ensure that the oblique slits of the warp or weft plate are fully exposed above the retaining assembly.

2. The projector light source with a latitude and longitude conical grid structure according to claim 1; the selection of the device for compensating for excessively high center brightness of the projector light, characterized in that: In the center of the LED array PCB board, some low-brightness LED beads are scattered to reduce the brightness of the central area. The specific PCB wiring method is as follows: insert low-brightness LED beads into a series LED circuit, and these low-brightness LED beads are distributed in the center of the LED array PCB board; or connect low-brightness LED beads individually in series and distribute them in the center of the LED array PCB board.

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