Projection Device Optical Component Beam Alignment
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Solution Overview
Problem
Projection devices face challenges in aligning red, green, and blue light beams due to variations in mechanical placement and orientation of light sources, leading to misalignment and distortion of projected images, as the beams are not consistently directed to the same point on the oscillating mirror and display screen.
Innovation Solution
A method involving fixing the positions of red, green, and blue light sources immovably and using an optical component to compensate for variations in their emission directions, ensuring that each beam is directed to the same point on the display screen, thereby eliminating the need for adjusting the light sources' positions and maintaining even glue distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If light sources are arranged in parallel with fast assembly, then productivity increases, but manufacturing precision deteriorates due to large positioning tolerances (+/-100 μm)
Solution Approach 1:
An optical component acts as an intermediary between the light sources and the oscillating mirror. This component compensates for the large positioning tolerances (+/-100 μm) by adjusting the optical path, allowing fast assembly while maintaining the precision needed to direct all light beams to the same point on the display screen.
Solution Approach 2:
The optical component adjusts optical parameters (beam direction, angle of incidence) to compensate for mechanical positioning variations. By changing these optical parameters, the system maintains precise beam alignment despite large initial positioning tolerances achieved through fast assembly processes.
2Manufacturing precision
If light source positions are adjusted to compensate for emission direction variations, then image quality improves, but device complexity increases due to additional adjustment mechanisms
Solution Approach 1:
The optical component serves as a mediator that handles the complexity of beam alignment. Instead of adjusting each light source position (which would require complex mechanical adjustment mechanisms), the optical component compensates for emission direction variations through optical adjustments, simplifying the overall device structure.
3Ease of manufacture
If light sources are secured with glue, then ease of manufacture improves, but reliability deteriorates due to displacement under thermal stress
Solution Approach 1:
The optical component acts as a compensatory intermediary that offsets the negative effects of using simple glue-based fixation. Even when thermal stress causes slight displacements of the light sources, the optical component adjusts the optical paths to maintain precise beam alignment, thereby preserving reliability while keeping manufacturing simple.
4Productivity
If mechanical placement tolerances are relaxed, then productivity increases, but manufacturing precision worsens leading to beam misalignment
Solution Approach 1:
The optical component is the key intermediary that decouples productivity from precision. It allows the system to accept light sources with relaxed mechanical placement tolerances (high productivity) and still achieve precise beam direction control (high manufacturing precision) by compensating for positioning variations optically.
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 approach ensures that light beams are accurately aligned, resulting in improved image definition and reduced susceptibility to displacement over time and temperature, maintaining image clarity and stability.
Implementation Method 1
positioning an optical component, which is configured to deflect light, such that it can receive red, green and blue light beams outputted from the red, green and blue light sources respectively
Data Source
AI summary
The present disclosure provides a projection device and manufacturing method, comprising the steps of fixing the positions of a red light source, green light source and blue light source so that the light sources are immovable; providing a mirror which is configured to oscillate such that it can scan light it receives across a display screen; positioning an optical component, which is configured to deflect light, such that it can receive red, green and blue light beams outputted from the red, green and blue light sources respectively; adjusting the optical component such that the optical component compensates for variation between the light sources, in the direction in which the red, green and blue light beams are output from the red, green and blue light sources, so that each of the red, green and blue light beams are directed to the same point on the display screen.