Overlapping Sub-Frame Projection for High Lumen Output

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Solution Overview

Problem

Existing projection systems face challenges in achieving high lumen levels efficiently, particularly in applications requiring greater than 10,000 lumens, due to high costs, limited fault tolerance, and issues with color accuracy and resolution, especially with single light source systems that suffer from sequential color artifacts and inefficient spectral usage.

Innovation Solution

The method involves generating and projecting overlapping single-color sub-frames using multiple projectors with different spectral distributions, optimizing sub-frame values to minimize color artifacts and enhance resolution and brightness, while utilizing individually designed light sources and filters to achieve efficient spectrum utilization and high-fidelity color projection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a single high-output projector is used to achieve high lumen levels, then the system is simple and reliable, but the lumen value per dollar is low and fault tolerance is poor

Engineering Contradiction:
Improvelumen outputVSAvoidsystem complexity
Core Design Contradiction:
Illumination intensityVSDevice complexity

Solution Approach 1:

The patent combines multiple low-output projectors into a single projection system where their outputs are superimposed on the same screen. This merging approach achieves high lumen levels (greater than 10,000 lumens) by adding the light output of multiple projectors together, while maintaining simplicity and reliability through the use of standard, off-the-shelf projector components rather than requiring specialized high-output projector hardware.

Inventive Principle:
Principle #5Merging (Combining)

2Device complexity

If conventional single light source projection systems use RGB color wheels to produce multi-color images, then the system structure is simple, but sequential color artifacts are produced and light is wasted during blanking periods

Engineering Contradiction:
Improvesystem structureVSAvoidsequential color artifacts
Core Design Contradiction:
Device complexityVSObject-generated harmful factors

Solution Approach 1:

The patent segments the color projection task across multiple projectors, with each projector dedicated to projecting a single color (red, green, or blue) continuously. This eliminates the need for color wheels and blanking periods, as each projector maintains a steady stream of its designated color without temporal multiplexing, thereby eliminating sequential color artifacts while keeping individual projector structures simple.

Inventive Principle:
Principle #1Segmentation

3Manufacturing precision

If tiled projection is used to deliver very high resolution, then pixel count is maximized, but seams are difficult to hide and output is reduced to produce uniform tiles

Engineering Contradiction:
ImproveresolutionVSAvoidoutput brightness
Core Design Contradiction:
Manufacturing precisionVSIllumination intensity

Solution Approach 1:

The patent uses overlapping projection where the output of multiple projectors is superimposed on the same screen area rather than placing tiles adjacent to each other. This merging of overlapping images eliminates visible seams between projection areas while maintaining uniform brightness across the entire projected image, as the overlap region receives light from multiple projectors simultaneously.

Inventive Principle:
Principle #5Merging (Combining)

4Use of energy by moving object

If conventional projectors use broad spectrum light sources to cover RGB ranges, then enough energy in all colors is obtained, but spectral efficiency is sub-optimal and costs are high

Engineering Contradiction:
Improvespectral efficiencyVSAvoidcost
Core Design Contradiction:
Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The patent applies local quality by assigning each projector a specialized light source optimized for its specific color function. Instead of using broad-spectrum light sources that waste energy, each projector uses a light source with spectral characteristics tailored to its designated color (e.g., red-optimized sources for red projectors), thereby achieving high spectral efficiency while using cost-effective, targeted lighting solutions rather than expensive broad-spectrum sources.

Inventive Principle:
Principle #3Local quality

Data Source

PatentUS7407295B2Projection of overlapping sub-frames onto a surface using light sources with different spectral distributions
Publication Date: 2008.08.05 HEWLETT PACKARD DEVELOPMENT COMPANY LP
  • US7407295B2 patent drawing
  • US7407295B2 patent drawing
  • US7407295B2 patent drawing

AI summary

A method of displaying an image with a display system includes receiving image data for the image. The method includes generating a first sub-frame and a second sub-frame corresponding to the image data. The method includes projecting the first sub-frame onto a target surface using a first projector light source. The method includes projecting the second sub-frame onto the target surface using a second projector light source, wherein the first and the second sub-frames at least partially overlap on the target surface, and wherein the first and the second light sources have substantially different spectral distributions.