Optical Engine Module No Air Gap Heat Dissipation

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Solution Overview

Problem

Current optical engine systems face challenges with increased back focus and light leakage due to the addition of off-ray heatsinks, which complicates lens manufacturing and affects image resolution in 4K projection devices.

Innovation Solution

An optical engine module configuration that includes a light valve module, an optical prism, and a first connecting layer with no air gap between them, allowing the image light beam to pass through, thereby reducing the distance from the projection lens to the light valve module and enabling space for an actuating module and heat dissipation element, even with a short back focus projection lens.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If an off-ray heatsink is added to absorb invalid beams, then light leakage is prevented, but back focus increases and manufacturing cost increases

Engineering Contradiction:

Improvelight leakageVSAvoidback focus

Core Design Contradiction:

Object-affected harmful factorsVSLength of stationary object

Solution Approach 1:

The patent extracts the heat dissipation function from a separate off-ray heatsink component and integrates it into the projection lens assembly. The lens housing directly contacts the light valve module to absorb heat, eliminating the need for additional heat dissipation components and reducing back focus distance.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent merges multiple functions into the projection lens assembly: the lens housing serves both as a structural support and as a heat dissipation element by directly contacting the light valve module. This integration eliminates the need for separate off-ray heatsink components.

Inventive Principle:

Principle #5Merging (Combining)

2Object-affected harmful factors

If an off-ray heatsink is added to absorb invalid beams, then light leakage is prevented, but manufacturing cost increases due to re-opening the mold

Engineering Contradiction:

Improvelight leakageVSAvoidmanufacturing cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent merges the heat dissipation function into the existing projection lens housing structure. This integration allows the lens to be manufactured as a single component without requiring additional molding operations or assembly steps, thereby avoiding increased manufacturing costs.

Inventive Principle:

Principle #5Merging (Combining)

3Length of stationary object

If the distance from projection lens to light valve module is reduced, then back focus is shortened, but space for actuating module and heat dissipation element becomes insufficient

Engineering Contradiction:

Improveback focusVSAvoidspace for actuating module and heat dissipation element

Core Design Contradiction:

Length of stationary objectVSVolume of stationary object

Solution Approach 1:

The patent combines the heat dissipation function with the projection lens housing, eliminating the need for separate heat dissipation space. The lens housing itself contacts the light valve module to dissipate heat, freeing up space within the compact back focus distance.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The projection lens housing performs multiple functions: it supports the optical elements, provides structural integrity, and dissipates heat from the light valve module. This multi-functionality allows the system to maintain compact dimensions while accommodating all necessary components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 reduces the distance from the projection lens entrance to the light valve module, maintains image quality, and allows for the inclusion of actuating and heat dissipation elements, addressing the issues of back focus and light leakage in optical engine systems.

Implementation Method 1

The optical prism is disposed on a transmission path of the illumination light beam and configured to guide the illumination light beam to the light valve module and to guide an image light beam from the light valve module

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Implementation Method 2

The first connecting layer is disposed between the light valve module and the optical prism, and the image light beam from the light valve module sequentially passes through the first connecting layer and the optical prism to transmit in a direction. There is no air gap between the optical prism and the light valve module.

Methodology Applied

Scientific EffectOptical coupling:

Data Source

PatentUS20240361679A1Optical engine module and projection device

Publication Date: 2024.10.31 CORETRONIC CORPORATION

AI summary

An optical engine module, configured to receive an illumination light beam, includes a light valve module, an optical prism, and a first connecting layer. The optical prism is disposed on a transmission path of the illumination light beam and configured to guide the illumination light beam to the light valve module and to guide an image light beam from the light valve module. The light valve module is disposed on the transmission path of the illumination light beam from the optical prism and configured to convert the illumination light beam into the image light beam. The first connecting layer is disposed between the light valve module and the optical prism. The image light beam from the light valve module sequentially passes through the first connecting layer and the optical prism to transmit in a direction. There is no air gap between the optical prism and the light valve module.