Light Combining Prism Assembly for Faster RGB Image Alignment
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Solution Overview
Problem
Existing three-chip digital projectors face challenges in aligning red, green, and blue light images due to high mechanical tolerance requirements and complex calibration processes, leading to manufacturing inefficiencies and image quality issues.
Innovation Solution
A light combining module with a positioning component, including a base and cover body, that securely holds a light combining prism and aligns it with a light source component, allowing direct alignment of light images with reference planes, simplifying calibration steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a multi-axis positioner is used to align red, green, and blue light images with the light combining prism, then alignment precision can be achieved, but the calibration process becomes complex and time-consuming
Solution Approach 1:
The patent applies preliminary action by pre-designing the positioning component with built-in alignment features that automatically position the light source component relative to the light combining prism. The positioning component includes a base with a first surface and a cover body with a second surface that are configured to guide and align the light source component during assembly, eliminating the need for complex post-assembly calibration adjustments.
2Manufacturing precision
If manual calibration adjustments are performed to align light images, then alignment accuracy can be improved, but manufacturing time increases
Solution Approach 1:
The positioning component is designed to be self-aligning through its geometric features. The base and cover body incorporate shaped surfaces that naturally guide the light source component into the correct position during assembly. This self-alignment capability eliminates the need for time-consuming manual calibration adjustments while maintaining high alignment accuracy, thereby improving manufacturing efficiency.
3Adaptability or versatility
If the light source component is positioned separately from the light combining prism, then assembly flexibility is improved, but alignment difficulty increases
Solution Approach 1:
The patent merges the positioning function and alignment function into a single integrated positioning component. This component combines the base, cover body, and light source component mounting features into one unified structure that simultaneously provides assembly flexibility and alignment ease. The integrated design allows the light source component to be positioned and aligned in a single assembly operation without requiring separate positioning and alignment steps.
Data Source
AI summary
A light combining module includes: a positioning component, including a base and a cover body connected to the base; a light combining prism, sandwiched between the base and the cover body; and a light source component, attached to the positioning component and including a panel frame and a light source panel, the panel frame including a first surface facing the positioning component, and the light source panel including a light-emitting surface facing the positioning component. The first surface and the light-emitting surface are substantially coplanar.