Light Source Device Lens Array Orientation for Mounting Error Tolerance

Solution Overview

Problem

Existing projector technologies using solid-state light sources face inefficiencies due to mounting variations, leading to decreased light use efficiency as the emitted light is not effectively utilized, especially when the secondary light source image shifts off the lenses, resulting in poor homogeneity and reduced brightness.

Innovation Solution

A light source device configuration with a collimating optical system, a first lens array of small lenses, and a second lens array with lenses oriented to accommodate potential mounting errors, ensuring the secondary light source image remains aligned and efficiently enters the optical system, enhancing light homogeneity and use efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional illumination devices are used without considering mounting variation, then the structure is simple, but light use efficiency decreases due to misalignment

Engineering Contradiction:

Improvelight use efficiencyVSAvoidmounting alignment precision

Core Design Contradiction:

Loss of energyVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-configuring the optical system with a lens array where each lens has a larger aperture than the light emission area. This preliminary design choice ensures that even when mounting variations occur, the light beams remain within the lens apertures, preventing misalignment issues before they can affect performance.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the parameter of lens aperture size relative to the light emission area size. By making the lens aperture larger than the light emission area, the system becomes tolerant to mounting variations. This parameter change transforms the system from being sensitive to alignment precision to being robust against such variations.

Inventive Principle:

Principle #35Parameter changes

2Illumination intensity

If mounting precision is not ensured, then manufacturing and assembly are easier, but the secondary light source image shifts off the lenses reducing brightness

Engineering Contradiction:

ImprovebrightnessVSAvoidmounting alignment precision

Core Design Contradiction:

Illumination intensityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-configuring the optical system with a lens array where each lens has a larger aperture than the light emission area. This preliminary design choice ensures that even when mounting variations occur, the light beams remain within the lens apertures, preventing misalignment issues before they can affect performance.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the parameter of lens aperture size relative to the light emission area size. By making the lens aperture larger than the light emission area, the system becomes tolerant to mounting variations. This parameter change transforms the system from being sensitive to alignment precision to being robust against such variations.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If the light beam is not properly collimated and directed, then the optical system is simpler, but light homogeneity deteriorates

Engineering Contradiction:

Improvelight homogeneityVSAvoidoptical system complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the optical system into multiple lens units arranged in an array. Each lens independently processes a portion of the light beam, contributing to the overall homogeneity. This segmentation allows the system to achieve good light homogeneity through the collective action of multiple simple lens elements rather than requiring a single complex optical component.

Inventive Principle:

Principle #1Segmentation

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 configuration significantly improves light use efficiency by maintaining alignment and homogeneity even with mounting errors, resulting in brighter illumination and improved display quality in projectors.

Implementation Method 1

a collimating optical system, to which a light beam bundle emitted from the light source array is input

Methodology Applied

Scientific EffectCollimation: Lens

Implementation Method 2

a first lens array including a plurality of first small lenses, to which the light beam bundle having been transmitted through the collimating optical system is input, and a second lens array disposed in a subsequent stage of the first lens array

Methodology Applied

Scientific EffectRefraction: Lens

Data Source

PatentUS10057553B2Light source device, illumination device, and projector

Publication Date: 2018.08.21 SEIKO EPSON CORP

AI summary

A light source device includes a light source array including at least one light emitting part, a collimating optical system that receives a light beam bundle emitted from the light source array, a first lens array including a plurality of first small lenses that receives the light beam bundle having passed through the collimating optical system, and a second lens array that is disposed in a subsequent stage of the first lens array and includes a plurality of second small lenses corresponding respectively to the first small lenses. The planar shape of the light emission area of the light emitting part has a short-side direction and a longitudinal direction. The planar shape of the second small lens has a longitudinal direction. The short-side direction of the light emission area crosses the longitudinal direction of the second small lens.