Projector Illumination Optics for Tolerance-Resilient Color Beam Collimation
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Solution Overview
Problem
The issue of positioning tolerance becomes prominent in miniaturized projectors due to the use of precision machining processes, increasing product cost and reducing optical efficiency.
Innovation Solution
An illumination system with a light source module, light splitting and combining element, beam expanding and collimating module, and light combining module, which aligns and collimates color beams to improve optical efficiency and reduce mechanism tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precision machining processes are used to reduce positioning tolerance in miniaturized projectors, then positioning accuracy is improved, but product cost increases
Solution Approach 1:
The patent replaces mechanical precision machining with optical design solutions. By using optical elements and beam path design, the system achieves acceptable positioning accuracy without relying on expensive precision machining processes, thereby reducing manufacturing cost while maintaining performance
Solution Approach 2:
The patent changes the approach from controlling mechanical positioning parameters to optimizing optical parameters. By adjusting optical element positions, beam expansion ratios, and collimation parameters, the system compensates for positioning tolerances without requiring high-precision mechanical machining
2Volume of moving object
If optical elements are miniaturized to reduce projector size, then device volume is reduced, but positioning tolerance issues become more prominent
Solution Approach 1:
The patent introduces dynamic compensation mechanisms where optical elements can be adjusted or where the optical design inherently compensates for positioning variations. The beam expanding and collimating modules are designed to maintain performance despite small positioning deviations, effectively dynamicizing the tolerance compensation
Solution Approach 2:
The patent uses composite optical systems combining multiple elements (beam expanding module, collimating module, reflecting element) that work together to compensate for individual component positioning tolerances. The composite optical path design ensures that errors in one element are compensated by the others
3Ease of manufacture
If positioning tolerance is not controlled, then manufacturing cost is reduced, but optical efficiency decreases
Solution Approach 1:
The patent introduces intermediary optical elements (beam expanding module, collimating module) that act as mediators between the light source and subsequent optical components. These intermediaries compensate for positioning tolerances and ensure proper beam alignment, maintaining optical efficiency without requiring strict positioning control
Solution Approach 2:
The patent performs preliminary beam processing (expansion and collimation) before the light reaches critical optical components. This preliminary action ensures that the beam is properly conditioned and aligned in advance, compensating for subsequent positioning tolerances and maintaining optical efficiency
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
Enhances optical efficiency and reduces the impact of mechanism tolerance, improving product yield and color uniformity in projection devices.
Implementation Method 1
After the first color beam and the second color beam are transmitted to the light splitting and combining element, the first color beam and the second color beam are reflected by the light splitting and combining element
Implementation Method 2
The first color beam and the second color beam from the light splitting and combining element are expanded and collimated by the beam expanding and collimating module
Implementation Method 3
The third color beam from the light source module is reflected by the reflecting element and transmitted to the light combining module
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
An illumination system providing an illumination beam includes a light source module generating first to third color beams, a light splitting and combining element, a beam expanding and collimating module, a reflecting element, and a light combining module. the first and second color beams are reflected by the light splitting and combining element after being transmitted to the light splitting and combining element. Transmission paths of the first and second color beams leaving the light splitting and combining element are coincident. The first and second color beams from the light splitting and combining element are expanded and collimated by the beam expanding and collimating module and transmitted to the light combining module. The third color beam is reflected by the reflecting element and transmitted to the light combining module. The transmission paths of the first to third color beams after leaving the light combining module are coincident. A projection device is provided.