Projector Base Frame Gap for Thermal Deformation Control

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Solution Overview

Problem

Projectors experience shifts in projection position due to temperature-induced deformation of constituent members, leading to inaccurate image projection.

Innovation Solution

The projector design includes a base frame with a gap between the illumination and projection units, and the use of metal members for the base frame and fixing units to accommodate thermal expansion, preventing deformation and maintaining image stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If the illumination unit and projection unit are tightly fixed to the exterior enclosure, then the structural stability is improved, but the projection position shifts due to thermal expansion deformation

Engineering Contradiction:

Improvestructural stabilityVSAvoidprojection position accuracy

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The patent divides the optical system into separate units (illumination unit, image formation unit, projection unit) that are coupled together but allow relative movement. This segmentation enables each unit to accommodate thermal expansion independently while maintaining overall structural stability, preventing projection position shifts.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the physical state of the coupling mechanism from rigid to flexible, allowing the units to move relative to each other in response to temperature changes. This parameter change enables the system to adapt to thermal expansion while maintaining projection accuracy.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If the constituent members are made of synthetic resin, then the ease of manufacture is improved, but the deformation due to temperature change increases

Engineering Contradiction:

Improveease of manufactureVSAvoiddimensional stability

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The patent uses composite construction where synthetic resin components are coupled with metal components (such as the lens barrel and projection lens). This composite approach combines the ease of manufacture of plastics with the dimensional stability of metal, reducing thermal deformation while maintaining manufacturing efficiency.

Inventive Principle:

Principle #40Composite materials

3Temperature

If the cooling fan speed is increased to cool the light source, then the temperature control is improved, but the projection position adjustment time is extended

Engineering Contradiction:

Improvelight source temperature controlVSAvoidprojection position adjustment time

Core Design Contradiction:

TemperatureVSLoss of time

Solution Approach 1:

The patent separates the thermal management function from the optical alignment function by using independent mounting structures. The illumination unit can be cooled independently without affecting the projection unit's position, allowing parallel operation of cooling and projection functions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces flexible coupling mechanisms and mounting structures that act as intermediaries between the illumination unit and the projection unit. These intermediaries isolate the thermal effects from the optical alignment, allowing temperature changes without transmitting deformation to the projection position.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 effectively suppresses projection position shifts by allowing for thermal expansion without abutment and enhancing the modulus of elasticity, ensuring precise image projection.

Implementation Method 1

the illumination unit and the projection unit to which the image formation unit is coupled are disposed on the base frame in such a way that a gap is provided between the illumination unit and the projection unit... when the illumination unit and the projection unit deform due to a change in temperature, the gap can accommodate the amount of deformation

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

the use of metal members for the base frame and fixing units to accommodate thermal expansion, preventing deformation and maintaining image stability

Methodology Applied

Scientific EffectModulus of elasticity: Elasticity

Data Source

PatentUS9733554B2Projector having illumination unit and projection unit disposed on base frame

Publication Date: 2017.08.15 SEIKO EPSON CORP

AI summary

A projector includes an illumination unit having an optical system including a light source apparatus, an image formation unit having an optical system including liquid crystal panels, a projection unit having an optical system including a projection lens, and a base frame on which the illumination unit and the projection unit to which the image formation unit is coupled are disposed, and a gap is provided between the illumination unit and the projection unit.