Optical Apparatus With Metal Holders For Pico-Projector Alignment
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Solution Overview
Problem
The miniaturization of pico-projectors for portable devices leads to complex optical axis alignment and high production costs, with challenges in heat dissipation due to limited space and increased power consumption.
Innovation Solution
An aligning method and optical apparatus that fix lenses and a beam combining unit on a base, using jigs to adjust light emitting units for precise alignment, simplifying the process while maintaining accuracy, and incorporating metal holders for improved heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple laser light sources are used to achieve high image luminance and small volume, then the projection resolution can be improved, but the optical axis alignment becomes complex and production costs increase
Solution Approach 1:
The patent combines multiple laser light sources (red, green, blue lasers) and their corresponding optical components (lenses, mirrors) into a single integrated optical module. This merging approach maintains the ability to produce high-resolution projection through multiple light sources while simplifying the overall alignment process by treating them as a unified assembly rather than separate components requiring individual alignment.
Solution Approach 2:
The optical components including lenses and mirrors are pre-aligned and fixed relative to each other during module assembly, before the entire module is installed in the projector. This preliminary alignment action eliminates the need for complex real-time adjustment of multiple degrees of freedom during production, thereby reducing alignment complexity while maintaining projection resolution.
2Volume of moving object
If the pico-projector volume is minimized for portability, then the device becomes suitable for portable applications, but the heat dissipation capability deteriorates
Solution Approach 1:
The patent applies different material properties to different parts of the optical module. Specifically, metal holders and fixtures are used in regions where heat dissipation is critical, while other components maintain their functional materials. This local differentiation of material quality enables effective heat dissipation in the compact structure without compromising the overall miniaturization of the projector.
3Manufacturing precision
If the optical components are precisely aligned to achieve ideal alignment precision, then the projection quality is improved, but the number of jigs and adjustment procedures increase
Solution Approach 1:
The optical system is divided into separate functional modules (laser modules, optical combining module, projection module), each with its own alignment requirements. By segmenting the system, each module can be aligned and tested independently using simpler, dedicated jigs, rather than requiring complex multi-degree-of-freedom adjustment mechanisms for the entire system. This segmentation maintains alignment precision while reducing production complexity.
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
Simplifies the optical alignment process, reduces the need for complex jigs, and enhances heat dissipation, enabling mass production of pico-projectors with improved alignment precision and reduced production costs.
Implementation Method 1
locations of the light emitting units are respectively corresponded to locations of the lenses... light beams respectively emitted by the light emitting units are enabled to be combined by the beam combining unit after respectively passing through the lenses
Implementation Method 2
incorporating metal holders for improved heat dissipation
Data Source
AI summary
An optical apparatus comprises a fixing base; a plurality of light emitting units and a plurality of holders. The light emitting units emits a plurality of light beams and each light emitting unit has a holding portion. Each holder has an accommodating indentation for accommodating the corresponding light emitting unit. The accommodating indentation exposes the holding portion of the corresponding light emitting unit so that a jig holds the exposed holding portion and adjusts the position of the holder and the light emitting unit before the holder is fixed to the fixing base and then adjusts the position of the light emitting unit within the holder after the holder is fixed to the fixing base. And then the light emitting unit is fixed to the holder.