Micro Projector Lens Assembly for Compact, Low-Loss Optics
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Solution Overview
Problem
Conventional micro projectors have large volumes due to oversized lens groups and complex lens package structures, leading to increased fabrication costs, light loss, and decreased image quality, with alignment and packaging processes complicating production.
Innovation Solution
A compact micro projector design featuring a micro LED array display chip with a lens group supported by a bottom connector, integrated with a lens barrel to minimize size and light loss, and a semiconductor wafer with stacked lens wafers for efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional lens group structure is used, then light transmission function is achieved, but the projector volume increases and fabrication cost increases
Solution Approach 1:
The patent merges the lens group and lens package structure into an integrated unit where the lens group is directly mounted on the lens package substrate. This integration eliminates separate mounting components and reduces the overall projector volume while simplifying the fabrication process and reducing costs.
Solution Approach 2:
The lens package structure is designed to serve multiple functions: it supports the lens group, provides structural housing, and enables assembly with the micro LED display chip. This multi-functionality reduces the need for additional components, thereby reducing volume and fabrication complexity.
2Device complexity
If a complex lens package structure is used, then structural support is achieved, but device complexity increases and fabrication cost increases
Solution Approach 1:
The patent extracts and eliminates unnecessary intermediate components from the lens package structure. The lens group is directly mounted on a simplified lens package substrate without requiring complex intermediate mounting structures, thereby reducing device complexity and fabrication cost.
Solution Approach 2:
The lens package substrate integrates multiple structural functions into a single component, combining support, housing, and assembly features. This merging reduces the number of separate parts and simplifies the overall device structure.
3Volume of moving object
If oversized lens groups are used, then light transmission is achieved, but projector volume increases and image quality decreases
Solution Approach 1:
The patent optimizes the optical parameters of the lens group, including curvature radii, thickness, and material refractive indices, to achieve effective light transmission with a compact lens size. These parameter optimizations maintain image quality while reducing the required lens group volume.
Solution Approach 2:
The patent employs curved lens surfaces with optimized curvature radii to achieve efficient light focusing and transmission. The spherical and aspherical surface designs enable compact lens dimensions while maintaining high image quality through precise optical path control.
4Productivity
If conventional assembly processes are used, then components are assembled, but alignment difficulty increases and production efficiency decreases
Solution Approach 1:
The lens group is pre-mounted and aligned on the lens package substrate before final assembly with the micro LED display chip. This preliminary positioning ensures accurate alignment is achieved early in the assembly process, simplifying subsequent steps and improving production efficiency.
Solution Approach 2:
The mounting structure integrates the lens group positioning and fixation functions into a unified design that aligns with the micro LED display chip grid. This integration eliminates separate alignment procedures and simplifies the packaging process.
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
The design achieves a more compact structure, reducing fabrication costs and improving image quality while expanding application scope and production efficiency.
Implementation Method 1
A micro LED display chip with a micro LED display array
Implementation Method 2
a lens group for adjusting and transmitting the light of the image or video
Data Source
AI summary
A micro projector and a semiconductor wafer are provided. The micro projector includes a micro LED array display chip; and a lens group provided above the micro LED array display chip and supported by a bottom connector. The semiconductor wafer includes a micro LED wafer including a plurality of micro LED array display chips; and a plurality of lens wafers stacked on the micro LED wafer to form a micro projector array.