Beam Splitter Combiner Substrate Alignment for Projection
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Solution Overview
Problem
The challenge in projection apparatuses is the inefficiency in combining color beams due to their proximity, leading to light leakage and manufacturing difficulties, particularly when integrating light sources and beam splitters/combiners on a shared substrate, resulting in asymmetrical color output and increased manufacturing costs.
Innovation Solution
A beam splitter/combiner design utilizing a light-transmitting substrate with strategically placed light transmission elements, where the thickness of the substrate is adjusted to align the paths of different color beams, and the use of complete optical films reduces manufacturing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If light sources of various colors are placed closer together on the same substrate to reduce device size, then the projection apparatus size and manufacturing cost are reduced, but the combining efficiency of color beams deteriorates due to light leakage at the edges of the light-transmitting substrate
Solution Approach 1:
The patent divides the light-transmitting substrate into different zones with distinct optical coating regions for different color beams. Each color beam has its own designated transmission area, preventing edge incursion and light leakage. This segmentation allows multiple light sources to be placed close together while maintaining combining efficiency by ensuring each color beam stays within its allocated optical path.
2Volume of moving object
If the optical path is aligned to the boundary of the coated optical film to achieve compact integration, then the device size is reduced, but the manufacturing difficulty increases due to precise alignment requirements
Solution Approach 1:
The patent applies different optical coatings to different local regions of the light-transmitting substrate, creating zone-specific optical properties. Each zone is optimized for a particular color beam's transmission characteristics. This local quality approach allows the optical paths to be naturally separated by the coating boundaries rather than requiring precise alignment to them, simplifying manufacturing while maintaining compact size.
3Ease of manufacture
If complete optical films are used instead of zoned coatings to simplify manufacturing, then the manufacturing process is simplified and cost is reduced, but the precision of color beam separation deteriorates
Solution Approach 1:
The patent segments the light-transmitting substrate into multiple optical zones, each with its own coating region designed for specific color beam transmission. This segmentation enables complete optical films to be used in each zone rather than complex zoned coatings across the entire substrate, achieving both manufacturing simplicity and precise color beam separation by confining each color beam to its dedicated optical path region.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures aligned center axes of color beams, preventing light leakage and improving color uniformity while simplifying the manufacturing process and reducing costs by aligning light paths effectively.
Implementation Method 1
A first color beam incident on the first light-transmitting substrate is reflected by the first light transmission element and leaves the first light-transmitting substrate
Implementation Method 2
A second color beam incident on the first light-transmitting substrate passes through the first light transmission element, is reflected by the second light transmission element
Data Source
AI summary
A beam splitter/combiner includes a first light-transmitting substrate, a first light transmission element, and a second light transmission element. The first light-transmitting substrate has a first optical surface facing incident light and a second optical surface opposite to the first optical surface. The first light transmission element is disposed on the first optical surface. The second light transmission element is disposed on the second optical surface. A first color beam incident on the first light-transmitting substrate is reflected by the first light transmission element and leaves the first light-transmitting substrate. A second color beam incident on the first light-transmitting substrate passes through the first light transmission element, is reflected by the second light transmission element, then passes through the first light transmission element, and leaves the first light-transmitting substrate. Paths of the first color beam and the second color beam incident on or leaving the first light-transmitting substrate coincide.