Pattern Projector Convex Lens Design for Undistorted Output
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Solution Overview
Problem
Conventional pattern projectors project distorted patterns due to the hemispherical surface of their front covers, limiting the types of patterns that can be projected, including characters, and causing discomfort for viewers.
Innovation Solution
A pattern projector design featuring a housing with a base, power box, and cover, where the cover has a convex portion with an outer lens that protrudes to prevent distortion, and a projection device with a driver, driving shaft, and inner lens that forms dynamic light patterns without distortion, allowing clear projection of characters and varying lighting effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a hemispherical cover is used for the front surface, then the projector structure is simple and compact, but the projected pattern becomes severely distorted
Solution Approach 1:
The cover is divided into two functional parts: a hemispherical protective cover and a separate convex portion containing the outer lens. This segmentation allows the protective cover to maintain its simple hemispherical shape while the outer lens on the convex portion provides the necessary optical correction to eliminate pattern distortion.
Solution Approach 2:
The outer lens acts as an intermediary optical element between the light source and the projected pattern. This intermediate component corrects the optical path and compensates for the distortion caused by the hemispherical cover, enabling clear pattern projection without compromising the compact structure.
2Volume of moving object
If a hemispherical front surface is used, then the housing is compact, but the pattern including characters cannot be projected clearly
Solution Approach 1:
The optical system is segmented into the inner lens for light gathering and the outer lens on the convex portion for pattern formation. This segmentation enables the housing to remain compact while the outer lens ensures clear pattern projection including characters by correcting optical distortion.
Solution Approach 2:
The convex portion with the outer lens provides localized optical correction at the critical projection area. This local quality enhancement ensures that the pattern including characters is projected clearly without requiring the entire housing to be enlarged or redesigned.
3Adaptability or versatility
If the outer lens is made with multiple protrusions, then diverse patterns can be projected, but the lens manufacturing becomes more complex
Solution Approach 1:
The lens system is segmented into the inner lens and the outer lens with protrusions. The outer lens can be manufactured as a separate component with molded protrusions that define the pattern, allowing for easy replacement and variety of patterns without redesigning the entire lens system.
Solution Approach 2:
The outer lens with multiple protrusions serves multiple functions: it protects the inner lens, provides the projection aperture, and defines the pattern shape through its protrusions. This multi-functionality reduces the need for additional components and simplifies the overall manufacturing process.
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 solution ensures clear and undistorted pattern projection, including characters, enhancing viewer comfort and entertainment, while allowing for interchangeable covers to project different patterns and static or dynamic lighting effects.
Implementation Method 1
The outer lens has multiple protrusions disposed on the convex portion for forming a pattern
Implementation Method 2
The projection device is disposed in the chamber of the base and has at least one lighting member
Data Source
AI summary
A pattern projector has a housing and a projection device disposed in the housing. The housing has a base and a cover. The cover is disposed on the base and has a connecting portion connected to the base, a convex portion, and a datum plane. The convex portion protrudes out of a front surface of the connecting portion, and has an outer lens disposed on the convex portion. The datum plane is defined between the connecting portion and the convex portion. A maximum height is defined from an inner surface of the convex portion to the datum plane. A maximum inner diameter of the convex portion is defined on the datum plane. The maximum inner diameter is three times to eleven times as long as the maximum height. A pattern projected by the projection device will not be distorted.