Light Reflecting Element Hinge Rigidity Thermal Stress
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Solution Overview
Problem
The existing light reflecting elements in spatial light modulators have low rigidity due to thermal stress, leading to warping and a reduced light reflection efficiency and contrast, primarily because of the trench formation on the mirror plate which decreases the light reflecting surface area.
Innovation Solution
A light reflecting element with a support part and a hinge part, featuring a torsion bar portion, movable pieces, and a stress adjusting layer, where the support layer is formed from the first movable piece to the second movable piece, and a recess is provided between them, with the stress adjusting layer parallel to the light reflecting layer, enhancing rigidity and maintaining a large light reflecting surface area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a trench is formed in the central portion of the light reflecting surface of the mirror plate, then the hinge part can be positioned, but the rigidity of the entire mirror plate becomes low and the mirror plate is likely to warp due to thermal stress
Solution Approach 1:
The support layer is divided into multiple regions: a first region containing the trench for hinge positioning, and a second region extending from the first region to the light reflecting surface. This segmentation allows the trench to be confined to a specific area while the second region provides structural support to maintain rigidity and prevent warping.
Solution Approach 2:
The support layer is configured with different structural characteristics in different regions: the first region with the trench provides hinge positioning functionality, while the second region provides enhanced structural support. This local differentiation allows each region to fulfill its specific function without compromising the overall performance.
2Ease of operation
If a trench is formed in the mirror plate, then the hinge can be positioned, but the area of the light reflecting surface is reduced by the area of the trench
Solution Approach 1:
The support layer is segmented into a first region containing the trench and a second region extending toward the light reflecting surface. This segmentation confines the trench to a minimal area necessary for hinge positioning, while the second region ensures the light reflecting surface maintains its full area for optimal optical performance.
Solution Approach 2:
The trench is extracted and confined to a specific first region of the support layer, separate from the light reflecting surface area. This extraction allows the hinge positioning function to be achieved without encroaching on the light reflecting surface, thereby maximizing the effective reflective area.
3Ease of manufacture
If the mirror plate is made thinner to reduce manufacturing cost, then manufacturing cost decreases, but the mirror plate becomes more susceptible to warping due to thermal stress
Solution Approach 1:
The support layer is segmented with a second region that extends from the first region to the light reflecting surface, providing localized structural reinforcement. This allows the overall mirror plate to remain thin for cost-effectiveness while the second region of the support layer prevents warping by distributing thermal stresses.
Solution Approach 2:
The support layer is configured as a composite structure with a first region containing the trench and a second region providing structural support. This composite configuration allows the use of thinner materials overall while maintaining sufficient rigidity and warping resistance through the strategically designed second region.
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 significantly reduces warping, improves light reflection efficiency, and enhances contrast by canceling thermal stress-induced deformations, while maintaining a large light reflecting surface area without the need for thickening layers, thus reducing manufacturing costs.
Implementation Method 1
rigidity of the entire mirror plate is low and the mirror plate is likely to warp due to thermal stress
Data Source
AI summary
A light reflecting element includes a support part 21, a hinge part 30, and a light reflecting part 40, in which the light reflecting part 40 includes a support layer and a light reflecting layer 50, the hinge part 30 includes a torsion bar portion 31, extending portions 34A and 34B extending from sides of the torsion bar portion 31, and movable pieces 35A and 35B extending from ends of the extending portions 34A and 34B, an end of the torsion bar portion 31 is fixed to the support part 21, the hinge part 30 is capable of being twisted and deformed around an axis of the torsion bar portion 31, the support layer is fixed to the movable pieces 35A and 35B, a recess 41D is provided at least in a portion of the support layer facing a space 35D located between the first movable piece 35A and the second movable piece 35B, and a stress adjusting layer 91 is provided on the support layer in parallel to the light reflecting layer 50 and separated from the light reflecting layer 50.