Flexible PCB Integration for Pico-Projector Size Reduction
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Solution Overview
Problem
Conventional projectors face challenges in reducing size due to independent wiring paths between the control board and light modulating device and LED light source, making it difficult to design pico-projectors to a desired thickness.
Innovation Solution
Integrating the wiring paths into a single flexible printed circuit board, which is bent to position the light source device for emission, eliminating the need for additional components and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If two independent flexible printed circuit boards are used to connect the control board to the light modulating device and LED light source separately, then each component can be controlled independently, but the projector size cannot be reduced due to the complexity of wiring paths
Solution Approach 1:
The patent merges two separate flexible printed circuit boards into a single integrated flexible printed circuit board that connects the control board to both the light modulating device and the LED light source. This consolidation reduces wiring complexity and eliminates the need for separate mounting boards and connectors, thereby reducing the overall projector size while maintaining independent control capabilities for each component.
Solution Approach 2:
The integrated flexible printed circuit board serves multiple functions: it acts as both the connection path for the light modulating device and the LED light source, and provides mounting support for the LED light source. This multi-functional design eliminates the need for separate mounting boards and reduces the number of components, directly addressing the size reduction goal.
2Reliability
If separate mounting boards and connectors are provided for the LED light source, then reliable electrical connection is ensured, but the number of components increases and manufacturing cost rises
Solution Approach 1:
The patent combines the functions of the mounting board and connector into the integrated flexible printed circuit board. The LED light source is mounted directly on this single board, which also provides the electrical connection path to the control board. This merging maintains reliable electrical connections while reducing the total number of components and simplifying the assembly process.
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate components such as separate mounting boards and connectors. By directly integrating the LED light source mounting and electrical connection functions into the single flexible printed circuit board, the design removes redundant elements while preserving the essential electrical connection reliability.
3Ease of operation
If the projector is designed with conventional wiring paths, then ease of assembly is maintained, but the thickness dimension cannot be reduced to desired levels for pico-projector applications
Solution Approach 1:
The patent merges multiple wiring paths and mounting functions into a single flexible printed circuit board, which significantly reduces the thickness dimension of the projector. The integrated board allows for compact arrangement of components and shorter connection paths, achieving the desired thin profile for pico-projector applications while maintaining assembly simplicity through the unified structure.
Data Source
AI summary
A projector (1) includes a light source device (2), a light modulating device (5) configured to modulate a light beam emitted from the light source device, a projection optical device (7) configured to project the light beam modulated by the light modulating device, and a flexible printed circuit board (6), one end of which is connected to the light modulating device (5). The light source device (2) includes a light emitting device mounted on the flexible printed circuit board (6). The flexible printed circuit board is bent, whereby the light source device is disposed in an emission position where the light source device (2) emits the light beam to the light modulating device (5).