Projector light source with longitude and latitude conical surface grid structure

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] The present 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 fixture for assembling the light source. [Background Technology]

[0002] The development of projectors has gone through three stages, namely CRT projection technology, LCD projection technology and DLP projection technology developed in recent years; the core of the projector includes three main parts: projector structure components, optical engine (including lens group), electrical control and interface. The important component in the optical engine structure is the light source.

[0003] LCD (Liquid Crystal Display) projector: In recent years, LED light sources have been widely used in projectors: a single multi-core LED light source is covered with an aspheric lens, expanded and shaped, and then projected onto a light valve; it is widely used in small projectors. The light source for a single-chip color LCD projector is relatively simple. The specific method is: dozens of LED white light chip arrays are converged by an aspheric lens and then shaped by a lens, or directly reflected by a funnel-shaped reflective umbrella, and then projected onto the LCD light valve display panel, and then projected onto the screen by a lens group; but there are great deficiencies in efficiency, mainly because the scale of the multiple LED chip arrays is too large, and it is difficult to efficiently shape them into a collimated beam with a certain scattering angle quality.

[0004] At present, the problems with the light source of single-chip color LCD projectors are: the uniformity of screen brightness and insufficient brightness, because the reflections of aspherical lenses and funnel-shaped reflective umbrellas are not uniformly distributed in spatial solid angles; on the other hand, the light output ratios of the center and corners of the projector lens group are different, and the light output ratio of the center is often higher; the two factors combined cause the problem of screen brightness uniformity, and the center brightness is often greater than the corner brightness, and the edge brightness is greater than the corner brightness. [Summary of the invention]

[0005] The purpose of the present invention is to solve the shortcomings of the existing technology, solve the problems of uniformity and insufficient brightness of the screen and improve the efficiency of the light source, so as to arrange as many LED lamp beads as possible within the allowable range of heat generation.

[0006] The feature of the present invention is that the assembly of the tapered grid components of the warp and weft plates is possible by using creative tooling, thus reducing the cost to improve brightness and uniformity.

[0007] Content of the present invention:

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

[0009] LED array PCB board, longitude and latitude plate conical grid assembly, reflective enclosure, heat dissipation structure, shell; wherein the heat dissipation structure includes: heat sink, fairing and electric fan, the wind of the electric fan may pass through the fairing and blow directly on the heat sink; LED lamp beads arranged vertically and horizontally are installed on the LED array PCB board; the longitude and latitude plate conical grid assembly includes: warp plate and weft plate with oblique slits (notches) for mutual insertion, the oblique slits (notches) are characterized by a family of oblique slits that appear in pairs in the shape of an eight, one end of the oblique slits leads to the boundary of the long sides of the warp plate and the weft plate, and the warp plate and the weft plate are interwoven and inserted to form a longitude and latitude conical grid structure, which is composed of many four-sided pyramidal surfaces arranged vertically and horizontally, and the small area of ​​the cone surface is defined as the light entrance;

[0010] The installation relationship of each component and part is as follows:

[0011] The LED array PCB board is installed on the heat dissipation structure (usually aluminum), and the LED lamp beads on the LED array PCB board are directly connected to the entrance array surface of the conical grid component. Each LED lamp bead is located in the central area of ​​each entrance; in this way, the light emitted by each LED lamp bead at each angle is continuously reflected by the inner surface of the conical grid of the longitude and latitude plate. Due to the light-guiding relationship of the beam expansion cone, the angle between the reflected light and the main optical axis is reduced each time. The more reflections, the smaller the angle between the reflected light and the main axis. Finally, the light of the LED lamp bead is emitted by The large notch of the conical grid of the longitude and latitude plate (the large exit surface of the quadrilateral, that is, the bottom surface of the large quadrangular pyramid) is projected out, and the solid angle of the exit light distribution is greatly reduced, and it is concentrated in the direction of the main optical axis (the direction perpendicular to the PCB board of the LED); the light emitted by the entire longitude and latitude conical grid structure is then confined and reflected by the square barrel-shaped reflective enclosure, and a uniform light field (light beam) with a small divergence angle is obtained in the rectangular exit area of ​​the reflective enclosure, and finally coupled to the LCD light valve display screen and transmitted out, and then the lens group projects the image onto the screen to generate a projection image.

[0012] Uniformity analysis of emitted light:

[0013] First of all, the light emitting solid angle of each lamp bead on the LED array PCB board is very large, generally in the range of 60 degrees to 130 degrees. The method to reduce the distribution solid angle is to cover each LED lamp bead with a micro-LED lens or a conical (inverted funnel-shaped) reflective surface; but it is difficult for a lens of several millimeters to achieve a small distribution solid angle of less than 20 degrees; in terms of obtaining the uniformity of the square: because the distance from the single LED array PCB board with a small distribution angle is far away, it can receive the light of all the lamp beads, and at a close distance, it can only receive the light of a small number of lamp beads, and the closer the distance, the fewer the number of lamp beads that can receive light; in this way, the LED array PCB board and the LCD transmission light valve need to maintain a moderate distance (the position of the LCD transmission light valve is in the projection plane in the attached figure description), and this distance satisfies: the spot area of ​​a single LED lamp bead projected onto the LCD transmission light valve occupies 1 / 40 to 1 / 5 of the total area of ​​the LCD transmission light valve, so that there is sufficient uniformity.

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

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

[0016] The core structure of the special fixture for completing the latitude and longitude plate conical grid assembly fixture includes:

[0017] The warp plate (or weft plate) holding assembly, the upper baffle plate and the push plate; the basic installation relationship is: the warp plate (or weft plate) holding assembly and the upper baffle plate are maintained in relative position by the holding component, and can be removed when not needed so as not to interfere, the warp plate (or weft plate) is inserted into the oblique slit notch of the holding assembly, and all are inserted in place, and the insertion depth of the warp plate (or weft plate) needs to be kept just enough: the oblique slit of the warp plate (or weft plate) can be fully exposed to the outside of the holding assembly (usually the top); then the weft plates (or warp plates) are inserted one by one into the oblique slits of the warp plate (or weft plate) below; the insertion depth is limited by the limit bar, and the insertion The insertion depth is just enough to make the long side of the upper weft plate (or warp plate) just touch the bottom of the oblique slit of the lower warp plate (or weft plate), limiting its position and preventing it from falling further, and the entrance distance of the slit at the corresponding boundary of the upper plate is equal to the spacing at the bottom of the corresponding oblique slit of the lower plate (only after this, the insertion relationship between the upper and lower plates is established); after all the upper weft plates (or warp plates) are in place; move the upper baffle plate down to against the upper long side of the upper weft plate (or warp plate); then move the push plate upward, passing through the hollow part of the retaining component, and will be able to push the lower warp plate (or weft plate) to move upward until the warp plate and the weft plate are connected as a whole at one time.

[0018] Technical advances of the present invention:

[0019] The conical grid structure and tooling of the longitude and latitude plates not only greatly reduce the overall cost, but also greatly increase the light efficiency; in the center of the LED array PCB board, some sparsely distributed low-brightness LED lamp beads are set to greatly improve the brightness uniformity of the projection. [Drawings]

[0020] The present invention will be further described below in conjunction with a preferred embodiment;

[0021] [ Figure 1 ] Overall diagram of the projector light source constructed with a longitude and latitude cone grid

[0022] [ Figure 2 ] Schematic diagram of the projector light source disassembly of the longitude and latitude cone grid structure

[0023] [ Figure 3 ]、[ Figure 4 ] Schematic diagram of the cone grid structure of the longitude and latitude plates.

[0024] [ Figure 5 ]、[ Figure 6 ]、[ Figure 7 ]Diagram of the warp and weft plate assembly and fixture.

[0025] Description of labels:

[0026] (1) Conical grid structure of warp and weft plates

[0027] (1-2) Warp board

[0028] (1-3) Weft plate

[0029] (1-4) Oblique seam

[0030] (1-5) Bevel

[0031] (1-6) Funnel-shaped reflection unit

[0032] (1-7) Entrance

[0033] (2) LED array (PCB) board

[0034] (3) Reflective panels

[0035] (4) Heat dissipation structure

[0036] (4-1) Fairing

[0037] (4-2) Electric fan

[0038] (4-3) Heat sink

[0039] (5) Arrow

[0040] (6) Main optical axis

[0041] (7) Reflected light

[0042] (8)LED light beads

[0043] (9) Disassembly diagram

[0044] (10) Fixtures and fixtures

[0045] (10-1) Dimension plate retaining assembly

[0046] (10-2) Gap

[0047] (10-3) Upper baffle

[0048] (10-4) Push Plate

[0049] (10-5) Limit bar

[0050] (10-6) Spiral Wire

[0051] (11) Projection solid angle [Specific implementation method]

[0052] like[ Figure 1 ]、[ Figure 2 ] as shown:

[0053] The light source structure of the projector with a latitude and longitude cone grid structure comprises: an LED array PCB board (2), a latitude and longitude cone grid assembly (1), a reflective enclosure (3), a heat dissipation structure (4), and a housing; the heat dissipation structure (4) comprises: a heat sink (4-3), a fairing (4-1), and an electric fan (4-2), and the wind of the electric fan passes through the fairing, or the electric fan is blown directly onto the heat sink (4-3) without the fairing; LED lamp beads (8) arranged vertically and horizontally are installed on the LED array PCB board (2); the structure of the latitude and longitude cone grid assembly (1) comprises: In summary: oblique slits (1-4) for mutual insertion are provided on the warp plates (1-2) and the weft plates (1-3), and the angle between the oblique slits and the short side is called the oblique angle (1-5). The oblique slits (1-4) are characterized by a family of figure-eight shaped oblique slits that appear in pairs, and one end of the oblique slits reaches the boundary of the warp plates and the weft plates. The interweaving and insertion of the warp plates and the weft plates form a conical grid structure, which is an internal reflection unit constituting a plurality of funnel-shaped reflection units (1-6); the angle between two warp plates or two weft plates is the oblique angle (1-5), and when the oblique angle is equal to 0 degree, the angle is zero degree or is called parallel to each other.

[0054] 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 lamp beads on the LED array PCB board (2) are directly connected to the entrance (1-7) of the cone grid component (the small area surface of the cone is defined as the entrance) array surface, and each pair of LED lamp beads is located in the central area of ​​each entrance; thus, the light emitted by each LED lamp bead at each angle is continuously reflected by the inner surface of the conical grid of the longitude and latitude plate, and due to the light-guiding relationship of the beam-expanding cone, the angle between the reflected light (7) and the main optical axis is reduced each time, and the more times of reflection, the smaller the angle between the reflected light and the main axis; finally, L The light of the ED lamp beads is projected from the large openings of the conical grid of the longitude and latitude plates, and the solid angle of the output light distribution is greatly reduced (the angle with the main optical axis becomes smaller; the original 120-degree luminous interval of the LED can be concentrated into a 15-degree luminous interval), and is concentrated in the direction of the main optical axis (6), as shown in the LED projection solid angle (11); the light emitted by the entire longitude and latitude conical grid structure is then confined and reflected by the square barrel-shaped reflective enclosure (3), and a uniform light field with a small divergence angle is obtained in the rectangular exit area of ​​the reflective enclosure (3), and finally coupled to be incident on the LCD light valve display screen and transmitted out, and then the image is projected onto the screen by the lens group.

[0055] like[ Figure 3 ]、[ Figure 4 ] as shown:

[0056] The warp and weft plate conical grid structure (1) is composed of a warp plate (1-2) and a weft plate (1-3); a pair of oblique slits (1-4) are provided on the warp plate (1-2) and the weft plate (1-3); the angle between adjacent oblique slits is an oblique angle (1-5); the surface of the warp plate (1-2) and the 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-pyramid cone surface) and a light outlet (the large-area end of the 4-pyramid cone surface); the light emitted by the LED light bead (8) on the LED surface array (PCB) board (2) passes through the entrance (1-7), is reflected multiple times by the 4-pyramid cone surface, and then 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) (the direction perpendicular to the LED surface array (PCB) board (2)).

[0057] like[ Figure 5 ]、[ Figure 6 ]、[ Figure 7 ] as shown:

[0058] [ Figure 6 ] The figure framed by the dotted line at the bottom is the figure above after the weft plate (1-3) is pulled out; the oblique slits (1-4) are arranged in pairs in an eight-shaped pattern, and the angle between the eight-shaped patterns is an oblique angle (1-5); on the two lintels of the weft plate holding assembly (10-1) of the fixture (10), an oblique notch (10-2) matching the oblique angle (1-5) is opened; the width of the notch (10-2) is slightly larger than the thickness of the warp plate and the weft plate, and can just insert the weft plate and the warp plate; the state after the weft plate (1-3) is removed from the weft plate holding assembly (10-1) is as shown in the disassembly diagram (9).

[0059] [ Figure 5] is a core structure of a special tooling fixture (10) for completing the tooling of the warp and weft plate conical grid assembly, which includes: a weft plate holding assembly (10-1), an upper baffle plate and a push plate; its basic installation relationship is: the weft plate holding assembly (10-1) and the upper baffle plate (10-3) are held in relative position by a holding component, and can be removed when not needed so as not to interfere, the weft plate is inserted into the inclined groove notch (10-2) of the weft plate holding assembly (10-1) and fully inserted into place; then The warp plates are inserted into the oblique notches (10-2) of the weft plate holding assembly (10-1) below one by one; the insertion depth is limited by the top of the limit lever (10-5) on the weft plate holding assembly (10-1) so that the warp plates do not continue to fall, and the insertion depth is just enough to make the long side of the upper weft plate just touch the bottom of the lower warp plate (10-2), and the oblique seam of the upper weft plate just aligns with the bottom of the oblique seam of the lower warp plate; after all the upper weft plates are arranged, the warp plates need to be kept The insertion depth is just enough to: expose the oblique seam of the warp plate completely; move the upper baffle plate to abut against the upper long side of the weft plate (or warp plate) above; the elastic deformation capacity of the weft plate and the warp plate can withstand a certain processing error; the push plate (10-4) moves upward and passes through the central area (lower end opening) of the inserted weft plate holding 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 baffle plate. After the oblique seams of the warp plates are inserted into all the notches to a matching depth and firmly inserted, the one-time synchronous overall docking of the warp plates and the weft plates is completed; the upper baffle plate (10-3) and the push plate (10-4) are moved along the direction of the arrow (5); the upper baffle plate (10-3) stops moving when it touches the warp plate, and the push plate (10-4) continues to move upward after it touches the weft plate; when the push plate (10-4) passes through the central area opening of the weft plate holding assembly (10-1), the one-time overall docking of the warp plates and the weft plates is completed.

Claims

1. The projector light source with longitude and latitude cone grid structure, the basic structure includes: LED array PCB board, latitude and longitude plate conical grid assembly, reflective enclosure, heat dissipation structure, shell; wherein the heat dissipation structure includes: heat sink, fairing and electric fan, or the electric fan directly blows the heat sink; LED lamp beads arranged vertically and horizontally are installed on the LED array PCB board; the installation relationship of each component and part includes: the LED array PCB board is installed on the heat dissipation structure, and the LED lamp beads on the LED array PCB board are directly connected to the entrance of the conical grid assembly, and each LED lamp bead is in the central area of ​​the entrance; in this way, the light emitted from each LED lamp bead at each angle is not The reflection is interrupted, so that the angle between each reflected light and the main optical axis is cumulatively reduced, and the light distribution projected through the large opening of the cone grid will be concentrated in the direction of the main optical axis; the light emitted by the entire longitude and latitude cone grid structure is then confined and reflected by the square barrel-shaped reflective enclosure, and a uniform light field with a small divergence angle is obtained in the rectangular exit area of ​​the reflective enclosure, and finally coupled to the LCD light valve display screen at the exit of the reflective enclosure; the brightness of the LED lamp beads arranged vertically and horizontally on the LED array PCB board is the same or different, which is used to obtain the device selection to compensate for the excessively high central brightness of the projector; Its characteristics are: a warp and weft plate conical grid component is covered on the LED array PCB board, or a micro LED lens is covered on each LED lamp bead; the warp and weft plate conical grid component includes: a warp plate and a weft plate with oblique slits and notches for mutual insertion, the oblique slits and notches are characterized by a family of oblique slits that appear in pairs in the shape of a figure eight, one end of the oblique slits leads to the boundary of the long sides of the warp and weft plates, and the warp and weft plates are interwoven and inserted into each other to form a warp and weft conical grid structure, which is composed of many four-sided pyramidal surfaces arranged vertically and horizontally, and the small area of ​​the pyramidal surface is defined as a light entrance; in the tooling for completing the production of the warp and weft plate conical grid component, a warp plate or weft plate holding component is used as a fixture for simultaneously fixing the warp plate or weft plate: an oblique slit or notch is opened on the top of the holding component to allow the warp plate or weft plate to be inserted, and the depth of the oblique slit or notch is just enough to allow the oblique slits opened on the warp or weft plate to be fully exposed above the holding component.

2. The projector light source of the latitude and longitude cone grid structure according to claim 1, characterized in that: The device selection for compensating for the excessively high central brightness of the projector is to set some sparsely distributed low-brightness LED lamp beads in the central part of the LED array PCB board to reduce the brightness of the central area. The specific PCB wiring method is: inserting a low-brightness LED lamp bead device into a series LED circuit, and the low-brightness LED lamp bead is just distributed in the central part of the LED array PCB board; or connecting the low-brightness LED lamp bead devices in series separately and distributing them in the central part of the LED array PCB board.

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