Optical Module Frame with Reinforced Shaft for Stable Actuation
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Solution Overview
Problem
In projector systems, the uniform thickness of metal frame bodies leads to simultaneous deformation of frame and shaft portions during actuation, affecting actuation stability and response speed due to similar structural strengths.
Innovation Solution
The optical module design includes a frame body with a shaft portion and frame portion, where the reinforcement structure and positioning structures extend in specific directions to create a greater structural strength in the frame portion compared to the shaft portion, allowing the shaft to withstand deformation stress and improve actuation stability and response speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a uniform thickness metal frame body is used, then manufacturing is simple, but both frame portion and shaft portion deform simultaneously during actuation, reducing actuation stability and response speed
Solution Approach 1:
The frame body transitions from uniform thickness to non-uniform thickness distribution. The shaft portion has reduced thickness (t1) compared to the frame portion (t2), creating localized structural differences. This allows the shaft to be more flexible while the frame remains rigid, ensuring stable actuation where only the shaft deforms during operation.
Solution Approach 2:
The frame body is segmented into distinct functional zones: the shaft portion for rotation and deformation, and the frame portion for structural support. This segmentation is achieved through different thickness regions and the addition of reinforcement structures, allowing each part to perform its specific function independently during actuation.
2Quantity of substance
If a uniform thickness metal frame body is used, then material usage is uniform, but structural strengths of frame portion and shaft portion are similar, causing simultaneous deformation and reducing response speed
Solution Approach 1:
The thickness parameter is locally optimized: the shaft portion has thickness t1 while the frame portion has greater thickness t2. This local differentiation creates the desired strength gradient where the shaft is more compliant for rapid response while the frame provides structural stability, directly improving actuation response speed.
Solution Approach 2:
The thickness parameter of the frame body is changed from a uniform value to a spatially varying value. By reducing thickness in the shaft region and maintaining or increasing it in the frame region (enhanced by reinforcement structures), the structural strength distribution is adjusted to enable faster response while maintaining overall rigidity.
3Strength
If reinforcement structures are added to the frame body, then structural strength of frame portion increases, but device complexity increases
Solution Approach 1:
The reinforcement structures are integrated directly into the frame body as a unified component rather than separate attachments. The reinforcement regions are formed as continuous extensions of the frame portion with varying thickness, combining the frame and reinforcement functions into a single manufactured part, thus increasing strength without proportionally increasing assembly complexity.
Solution Approach 2:
Reinforcement structures are added only in specific regions where structural strength is needed, rather than uniformly throughout the entire frame body. This localized reinforcement approach increases strength where necessary while minimizing the overall complexity and material usage.
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 design enhances actuation stability and response speed of the optical module, leading to increased image resolution in projection devices by ensuring the shaft portion bears most of the deformation stress while maintaining structural integrity.
Implementation Method 1
the shaft portion bears most of the deformation stress while maintaining structural integrity
Implementation Method 2
the image beam is refracted to another position by the glass, thereby achieving an effect of increasing a resolution of a projected image
Data Source
AI summary
An optical module includes a frame body and an optical element. The frame body includes at least one fixing portion, at least one frame portion and at least one shaft portion connected to the fixing portion and the frame portion. The frame portion includes at least one main body, a plurality of positioning structures and at least one reinforcement structure. A part of an inner side surface of the main body is bended toward a thickness direction of the frame body to form the positioning structures, and the reinforcement structure is connected to the main body and extends in the thickness direction. The frame portion oscillates relative to the fixing portion around the shaft portion. In the thickness direction, a sum of a height of the reinforcement structure and a thickness of the main body is greater than a thickness of the shaft portion.