Prism Module Spacer Bonding for Stable Air Gap Control
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Solution Overview
Problem
The interference caused by changes in the air gap between prisms in a prism module of a projection device due to temperature differences leads to deteriorated image quality.
Innovation Solution
A prism module manufacturing method involving a predetermined temperature difference between prisms, using an adhesive layer with spacers to maintain a consistent gap, preventing interference and potential separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an adhesive layer is used to connect the first prism and the second prism, then the prisms are joined together, but the air gap between the prisms changes during operation due to temperature differences, causing interference and deteriorated image quality
Solution Approach 1:
The patent introduces spacers with specific thickness to control and maintain a predetermined air gap distance between the first and second prisms. By changing the physical parameter of the adhesive layer (adding spacers to create air gaps), the patent prevents thermal expansion-induced contact while maintaining reliable spacing, thus resolving the contradiction between bonding strength and image quality stability.
Solution Approach 2:
The spacers act as intermediary elements between the first prism and the second prism. These spacers are embedded in the adhesive layer and provide a predetermined distance, preventing direct contact between the prisms during temperature changes. This intermediary structure maintains both the adhesive bonding and the stable air gap required for preventing interference.
2Strength
If the adhesive layer completely connects the first prism and the second prism, then strong bonding is achieved, but the prisms cannot accommodate thermal expansion differences, leading to potential rupture
Solution Approach 1:
The adhesive layer is segmented by embedding multiple spacers within it. This segmentation creates multiple small air gaps that allow the prisms to accommodate thermal expansion independently while still maintaining overall bonding. The adhesive layer is divided into multiple bonding regions separated by spacers, enabling differential movement without rupture.
Solution Approach 2:
By changing the adhesive layer structure from a complete continuous connection to a segmented connection with spacers, the patent allows the prisms to expand and contract independently during temperature changes. This parameter change in the adhesive layer configuration prevents structural rupture while maintaining bonding strength.
3Ease of manufacture
If the air gap between the first prism and the second prism is not controlled, then manufacturing is simpler, but interference occurs during operation due to gap changes, deteriorating image quality
Solution Approach 1:
The spacers serve as intermediary elements that automatically maintain a predetermined air gap distance during assembly. By embedding spacers in the adhesive layer, the patent provides a simple yet effective way to control the air gap consistency without complex assembly procedures, thus achieving both ease of manufacture and manufacturing precision.
Solution Approach 2:
The spacers embedded in the adhesive layer automatically maintain the predetermined air gap during assembly and operation. The structure is self-regulating, where the spacers inherently prevent the prisms from coming into contact or having excessive gap, eliminating the need for complex external control mechanisms during manufacturing.
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
The method maintains a consistent gap between prisms, improving image quality and preventing prism rupture, enhancing the reliability of the projection device.
Implementation Method 1
during an operation period of a projection device using this type of prism module, the image beam is likely to change the interference in the prism module due to the change of the air gap
Data Source
AI summary
A prism module manufacturing method includes the following steps of: adjusting a first prism and a second prism to have a predetermined temperature difference; using an adhesive layer to be partially connected between the first prism and the second prism so that there is a gap between the first prism and the second prism, wherein the adhesive layer includes a glue material and a plurality of spacers arranged in the glue material. The invention further provides a prism module and a projection device having the prism module. The prism module and the manufacturing method thereof of the invention avoid the interference problem in the prism module so that the image quality and reliability of the projection device can be improved.