Configurable Optical Coupling for Laser Projectors
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Solution Overview
Problem
Conventional optical designs for laser projection systems face challenges in maintaining brightness and color uniformity when different numbers of laser light sources are used, requiring distinct launch assemblies for each configuration.
Innovation Solution
An optical apparatus comprising an optical fiber, a configurable back plane assembly, and a condensing assembly, where the optical fiber is attached to the back plane and illuminates the condensing assembly, which forms a symmetrical pattern of spots on a mixing rod, allowing for flexible coupling of multiple optical fibers to achieve uniform illumination across various power levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If different launch assemblies are designed for each case (different numbers of lasers), then brightness and color uniformity is maintained, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent employs a universal launch assembly design that can accommodate different numbers of laser sources (2, 5, or any number) using the same optical components. The configurable back plane with adjustable fiber positions and the symmetric spot pattern design enable a single launch assembly to serve multiple projection system configurations, eliminating the need for different specialized assemblies for each laser count.
Solution Approach 2:
The launch assembly is segmented into modular components: a configurable back plane with multiple fiber position options, a condensing assembly, and a mixing rod. This segmentation allows flexible configuration of optical fibers at different positions on the back plane to create appropriate spot patterns on the mixing rod input face, enabling adaptation to different laser numbers without redesigning the entire assembly.
2Ease of manufacture
If a fixed launch assembly design is used, then manufacturing is simplified, but adaptability to different projection system power levels is reduced
Solution Approach 1:
The launch assembly incorporates dynamic configurability through the configurable back plane, which allows optical fibers to be positioned at different locations depending on the number of lasers used. This dynamic adjustment capability enables the same manufactured assembly to adapt to various projection system power levels and laser configurations, maintaining both ease of manufacture and versatility.
3Manufacturing precision
If optical fibers are positioned to create symmetrical spot patterns on the mixing rod, then illumination uniformity is improved, but the complexity of fiber positioning increases
Solution Approach 1:
The configurable back plane is pre-designed with specific fiber position locations that correspond to symmetrical spot patterns on the mixing rod input face. These pre-determined positions allow installers to achieve uniform illumination by simply placing fibers at the predetermined locations, rather than requiring complex calculations or adjustments during installation. The symmetric geometry of the back plane positions is engineered in advance to produce the desired uniform spot patterns.
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 enables improved uniformity in brightness and color across different projection systems by adjusting the positions of optical fibers within the configurable back plane assembly, allowing for efficient coupling of light from multiple lasers to a digital projector, regardless of the number of lasers used.
Implementation Method 1
The optical fiber attaches to a position of the configurable back plane assembly and illuminates the condensing assembly
Implementation Method 2
condensing the light from the optical fibers with a condensing assembly
Data Source
AI summary
An apparatus and method for flexible configuring of optical fibers to illuminate digital projectors. The optical fibers are attached to various positions of a configurable back plane assembly and a condensing assembly condenses the light beams prior to launch into the projector. Horizontal and vertical launch symmetries are maintained for any number of optical fibers between 1 and 9.