DLP Projector Resolution Multiplication via Multi-Source Synchronization
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Solution Overview
Problem
The resolution of Digital Light Processing (DLP) projectors is limited by the size of the Digital Micromirror Device (DMD) matrix, leading to high costs as the price of DLP projectors increases nonlinearly with resolution, and existing methods for enhancing resolution, such as tiling images, are inefficient.
Innovation Solution
A DLP projector system utilizing at least three monochromatic light sources, a DMD chip, and a synchronization control unit to project images defocused relative to each other on a defocused imaging plane, effectively increasing resolution by using monochromatic light sources to create a higher resolution image than the original projector capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the DMD matrix size is increased to improve resolution, then the projector resolution is improved, but the cost increases nonlinearly
Solution Approach 1:
The invention segments the imaging function by using multiple light sources (at least three) instead of relying solely on a larger DMD matrix. Each light source contributes to forming the final image, allowing the system to achieve higher effective resolution by combining multiple lower-resolution projections. This segmentation approach avoids the need for a single large, expensive high-resolution DMD while still achieving the desired resolution through coordinated projection from multiple sources.
2Measurement precision
If tiling methods are used to multiply resolution, then the effective resolution is enhanced, but the process becomes inefficient and time-consuming
Solution Approach 1:
The invention employs periodic action through synchronized temporal modulation of multiple light sources. Each light source is activated in a coordinated sequence with precise timing control, allowing the system to project multiple images that are combined to form a high-resolution final image. This periodic activation pattern enables efficient resolution multiplication without requiring sequential tiling operations, significantly improving image generation speed while maintaining high effective resolution.
3Measurement precision
If multiple light sources are used to multiply resolution, then the effective resolution is enhanced, but the system complexity increases
Solution Approach 1:
The invention applies universality by designing a system where multiple light sources share common optical components and control mechanisms. The projection lens, DMD chip, and synchronization control unit serve multiple functions by handling light from different sources. This multi-functionality approach allows the system to achieve enhanced resolution through multiple light sources while avoiding proportional increases in overall system complexity, as many components serve universal purposes across all light source channels.
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 approach enhances the effective resolution of DLP projectors by multiplying the original resolution, allowing for the creation of higher resolution images and 3D objects with reduced build times while maintaining good part resolution, and can be applied in additive manufacturing and other imaging technologies.
Implementation Method 1
at least one projection lens for refracting and projecting at least some of said monochromatic light beams for display
Implementation Method 2
at least one DMD chip for selectively reflecting at least some of said radiated monochromatic light beams from said at least three light sources towards said projection lens
Data Source
Figure 1~1A
Figure 2
Figure 3A~3C
AI summary
A DLP projector apparatus is provided for projecting a monochromatic display from plurality of monochromatic light sources. The DLP projector is adapted to radiate from each micromirror of its DMD chip an image comprising a plurality of radiated locations which are shifted with respect to each other. The DLP projector apparatus comprise a controller unit that is adapted to control the radiation from the plurality of light sources to the image according to a radiation scheme in an object production file. A DLP projector apparatus is also provided comprising an imaging table that is adapted to be moved in a plane perpendicular to an imaging beam of the projector. The movements of the table are coordinated and synchronized with the imaging scheme of the projector. The imaging scheme and the movements of the table are controlled according to a radiation scheme in an object production file.