Integrated PBS Array for LCOS Projectors
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Solution Overview
Problem
The high labor and low yield in hand-assembled polarizing beam splitters (PBS) for Liquid Crystal on Silicon (LCOS) projectors result in high manufacturing costs, contradicting the low-cost nature of LCOS imager systems, as these components require expensive polarization control components and manual assembly.
Innovation Solution
An integrated optical component array is fabricated using a support with stair steps and integral PBS cubes, allowing for massively parallel assembly and subsequent singulation, reducing manufacturing costs and eliminating the need for labor-intensive hand assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If polarizing beam splitters are hand-assembled, then assembly precision can be maintained, but labor content increases and yield decreases
Solution Approach 1:
The patent merges multiple PBS elements into a single integrated component array that is monolithically formed from one piece of optical material. This eliminates the need for hand assembly of individual PBS elements while maintaining optical precision, as the entire array is fabricated as a unified structure using precision machining and lamination processes.
Solution Approach 2:
The integrated PBS array serves multiple functions simultaneously - it acts as both a structural support and an optical component array. The stair-step configuration allows multiple PBS elements to be integrated into a single component that can be used in various projection applications, reducing the need for separate assembly operations.
2Reliability
If polarizing beam splitters are hand-assembled, then quality control can be maintained, but manufacturing cost increases
Solution Approach 1:
By combining multiple PBS elements into a single monolithically formed array, the patent eliminates costly hand assembly operations while maintaining quality control. The integrated structure ensures consistent optical performance across all elements without requiring manual alignment or assembly, thereby reducing manufacturing costs while preserving reliability.
Solution Approach 2:
The patent changes the manufacturing parameter from manual assembly to monolithic fabrication. This parameter change enables automated precision machining processes to replace labor-intensive hand assembly, maintaining optical quality while significantly reducing manufacturing costs through economies of scale and automated production.
3Adaptability or versatility
If PBS components are made for LCOS projectors, then system compatibility is achieved, but component cost offsets imager cost savings
Solution Approach 1:
The patent merges multiple PBS elements into a single integrated array that maintains full compatibility with LCOS projector systems. This consolidation reduces component costs by eliminating manual assembly operations and enabling automated production, while the optical performance and system compatibility remain unchanged, allowing the low-cost imager benefits to translate to overall system cost savings.
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 significantly reduces manufacturing costs and improves yield by enabling the production of low-cost, high-quality PBS components for LCOS projectors, making them more competitive in the market.
Implementation Method 1
a reflective polarizer disposed on a diagonal surface between the first prism and the second prism
Implementation Method 2
reflective polarizer disposed on a diagonal surface
Data Source
AI summary
The present disclosure provides an integrated optical component array and method of making an integrated optical component array useful for projection devices or other optical devices. The integrated optical component array can be a PBS array fabricated such that the individual PBS cubes having several elements can be assembled in a massively parallel manner and then singulated as individual optical components, and can result in a large reduction in manufacturing cost.