Projector Light Source Module With Connector-Free Laser Mounting
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Solution Overview
Problem
Existing light source modules for projectors require the use of male and female connectors, as well as multiple screws for assembly, leading to higher production costs due to the complexity and cost of these components.
Innovation Solution
A light source module design that eliminates the need for male and female connectors by using a heat sink, a laser assembly, a circuit board assembly, and lock members that pass through corresponding lock holes to secure the components, reducing the number of required screws and connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If male and female connectors are used to connect the laser assembly to the circuit board, then electrical connection is achieved, but production cost increases due to connector expense
Solution Approach 1:
The patent removes the connector component from the system by establishing direct electrical contact between the circuit board and laser assembly through conductive pins that extend through the circuit board and contact conductive pads on the laser assembly, eliminating the need for separate male and female connectors
Solution Approach 2:
The patent combines the electrical connection function with the mechanical mounting structure by integrating conductive pins into the circuit board assembly that simultaneously provide both structural support and electrical conductivity, merging what were previously separate functions
2Stability of the object's composition
If two sets of screws are used to lock the circuit board and laser assembly on the heat sink, then assembly stability is ensured, but processing cost increases due to additional positioning work
Solution Approach 1:
The patent merges the mounting function into a single integrated structure by having the circuit board assembly and laser assembly share common mounting holes in the heat sink, allowing both components to be secured with one set of screws rather than requiring separate mounting operations
Solution Approach 2:
The heat sink is designed with universal mounting holes that serve dual purposes: securing both the circuit board assembly and the laser assembly, making the mounting structure multi-functional and eliminating the need for separate positioning operations
3Reliability
If male and female connectors are used for connecting the laser assembly, then electrical connection is reliable, but device complexity increases due to additional components
Solution Approach 1:
The patent extracts and removes the connector components from the system, replacing them with a simplified direct-contact electrical connection method where conductive pins on the circuit board directly contact conductive pads on the laser assembly
Solution Approach 2:
Instead of using separate male and female connectors that mate together, the patent inverts the approach by having the circuit board itself provide the conductive connection through its pins, reversing the traditional connector architecture
Data Source
AI summary
A light source module, which includes a heat sink, a laser assembly, a circuit board assembly, a conductive material, and multiple lock members, is provided. The circuit board assembly includes a circuit board, which has an accommodating opening that corresponds to a beam emitter of the laser assembly. The lock members respectively pass through third lock holes of the circuit board assembly, second lock holes of the laser assembly, and first lock holes of the heat sink in sequence, thereby locking the circuit board assembly and the laser assembly on the heat sink. The accommodating opening of the circuit board exposes the beam emitter, and the conductive material connects two conductive pads of the laser assembly to two corresponding electroplated through holes, thereby enabling the laser assembly to be electrically connected to the circuit board assembly. A projector including the light source module is also provided.