Light Deflector with Polyhedron Beam Adjuster
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Light deflectors used in projection systems face challenges in maintaining high reliability due to environmental changes, particularly dust and humidity, which affect the movable mirror units, and existing solutions do not effectively manage unnecessary reflection light, leading to image noise.
Innovation Solution
A light deflector design that includes a movable mirror unit, a transparent member for hermetic packaging, and a polyhedron light-beam adjuster to minimize reflection by optimizing the refractive indices and angles, ensuring that unnecessary reflection light is guided away from the projection site, reducing image noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a semitransparent covering member is used to package the movable mirror unit for hermeticity, then reliability against dust and humidity is improved, but unnecessary reflection light is generated causing image noise
Solution Approach 1:
The patent converts the harmful reflection light generated by the semitransparent covering member into a beneficial effect by designing a light deflector that redirects this reflection light away from the projection site. The deflector transforms what was previously harmful (image noise) into a controlled optical path that eliminates the noise while maintaining the protective packaging
Solution Approach 2:
The patent introduces a light deflector as an intermediary element between the semitransparent covering member and the projection site. This deflector acts as a mediator that intercepts the reflection light from the covering member and redirects it to a different direction, preventing the harmful light from reaching the projection site while allowing the covering member to maintain its protective function
2Ease of operation
If the movable mirror unit is exposed to the environment for easier access, then ease of operation is improved, but oxidation and temperature changes affect reliability
Solution Approach 1:
The patent creates a hermetic packaging environment around the movable mirror unit that isolates it from the external environment. This inert atmosphere prevents oxidation and protects against temperature changes, dust, and humidity, thereby maintaining high reliability while the unit operates
3Object-generated harmful factors
If a polyhedron light-beam adjuster is added to manage reflection light, then image noise is reduced, but device complexity increases
Solution Approach 1:
The patent designs the polyhedron light-beam adjuster to serve multiple functions: it adjusts the light beam path, manages reflection light from the semitransparent covering member, and redirects unwanted light away from the projection site. By combining these functions into a single component, the patent reduces device complexity compared to using separate elements for each function
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
The solution enhances the durability and reliability of light deflectors by preventing oxidation and improving temperature stability, while minimizing image noise through effective management of reflection light, resulting in a more reliable and efficient projection system.
Implementation Method 1
In order to prevent a movable mirror unit that is driven when optical scanning is performed from being affected by dust particles or humidity, the movable mirror unit is packaged by covering a light-incident side of a housing in which the movable mirror unit is accommodated with a semitransparent covering member. Accordingly, hermeticity is achieved.
Implementation Method 2
a polyhedron light-beam adjuster to minimize reflection by optimizing the refractive indices and angles, ensuring that unnecessary reflection light is guided away from the projection site
Data Source
AI summary
A light deflector, a method of manufacturing the light deflector, and an image projector. The light deflector and the method includes forming a first wafer provided with a plurality of movable mirror units, bonding the first wafer to be sandwiched between a second wafer on which a plurality of base units are formed and a third wafer on which a plurality of spacers are formed, bonding a fourth wafer on which a plurality of transparent members are formed on the third wafer, bonding a plurality of polyhedron light-beam adjusters on the fourth wafer such that one of the plurality of polyhedron light-beam adjusters and the movable mirror unit become a pair, and cutting a wafer layered product of the first to fourth wafers for each area in which the light deflector is formed. The image projector includes the light deflector, and an image is projected by optical scanning.