Laser Light Source Module Layout for Uniform Projection Color
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Solution Overview
Problem
Current projection devices face challenges in achieving color uniformity and reducing volume and cost due to the use of thick glass optical elements for combining light, which increases additional costs and volume, especially when combining blue-green light with red light.
Innovation Solution
A light source module design utilizing a first and second laser array, reflective elements, and light splitting elements to guide light beams to an optical lens element, ensuring orthogonal projections of the light splitting elements overlap, thereby uniformizing light spots and reducing the need for thick glass components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thick glass optical elements are used for combining light, then color uniformity can be improved, but volume and cost increase
Solution Approach 1:
The patent divides the light combining function into multiple thin film optical elements (dichroic mirrors, beam combiners) arranged in a specific optical path configuration. Instead of using a single thick glass element, the light combining is achieved through sequential reflection and transmission through multiple thin layers, each designed to handle specific wavelength ranges. This segmentation allows for better color uniformity while maintaining compact volume.
Solution Approach 2:
The patent employs composite optical structures combining multiple thin film layers with different optical properties (dichroic coatings, beam splitting layers) to achieve the light combining function. These composite thin film structures replace the traditional thick glass element, providing superior wavelength-selective optical performance while significantly reducing the overall optical element thickness and system volume.
2Manufacturing precision
If thick glass optical elements are used for combining light, then color uniformity can be improved, but cost increases
Solution Approach 1:
The light combining function is segmented into multiple thin film optical elements with specific spectral characteristics. Each thin film layer can be manufactured using standard deposition techniques and then assembled into the optical train, which is more cost-effective than manufacturing and polishing a single thick glass element with complex internal structures. This modular approach reduces material costs and manufacturing complexity.
Solution Approach 2:
The patent changes the physical parameters of the optical elements from thick glass (high thickness, homogeneous material) to thin film structures (low thickness, layered composition with specific optical constants). This parameter change enables the use of conventional thin film deposition processes rather than expensive precision glass machining, thereby reducing manufacturing cost while achieving superior color uniformity through wavelength-selective optical paths.
3Manufacturing precision
If blue-green light is expanded to match red light, then color matching is improved, but additional cost and volume are incurred
Solution Approach 1:
Instead of expanding the blue-green light in the spatial dimension (which would increase volume), the patent uses wavelength-selective thin film optical elements to redirect different color components through different optical paths. The dimensionality change is achieved by utilizing the angular/spectral dimension through precise control of light reflection and transmission angles at each thin film interface, enabling color matching without spatial expansion.
Solution Approach 2:
The patent introduces thin film optical elements (dichroic mirrors, beam combiners) as intermediary components that mediate between the blue-green and red light paths. These intermediaries selectively reflect, transmit, and combine different wavelength components to achieve color matching, replacing the need for physical expansion of light beams and eliminating the associated volume increase.
4Manufacturing precision
If blue-green light is expanded to match red light, then color matching is improved, but additional cost is incurred
Solution Approach 1:
The patent uses thin film optical elements as intermediary components to achieve color matching between blue-green and red light. These intermediaries can be manufactured using standard thin film deposition processes and are significantly cheaper than the thick glass expansion components or additional optical systems that would be required to physically expand and match the light beams. The intermediary approach reduces both material and manufacturing costs.
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
Improves color uniformity and reduces the overall volume and cost by guiding light beams efficiently through reflective and splitting elements, eliminating the need for thick glass light combining elements.
Implementation Method 1
a first reflective element... a second reflective element... a third reflective element... a fourth reflective element
Implementation Method 2
The first light splitting element is configured to reflect the fourth light from the sixth reflective element and allow the first light from the first reflective element to pass through to the optical lens element. The second light splitting element is configured to reflect the second light from the fifth reflective element and allow the third light from the third reflective element to pass through to the optical lens element.
Data Source
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AI summary
A light source module including first and second laser arrays, first to six reflective elements, first and second light splitting elements, and an optical lens element is provided. The first laser array provides first light and second light. The second laser array provides third light and fourth light. The first light splitting element reflects the fourth light from the sixth reflective element and allows the first light from the first reflective element to pass through to the optical lens element. The second light splitting element reflects the second light from the fifth reflective element and allows the third light from the third reflective element to pass through to the optical lens element. Orthogonal projections of the first light splitting element and the second light splitting element on the optical lens element are partially overlapped.