Projector Light Adjuster Cover Member for Gear Protection
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Solution Overview
Problem
The assembly efficiency of optical diaphragm units in projectors is hindered by the need to separately attach motors and light shield bases to a common base plate, leading to reduced work efficiency and increased dust adhesion on gears, which affects reliability and noise levels.
Innovation Solution
A light adjuster design featuring a cover member that supports and rotates gears, reducing dust adhesion and noise, while allowing for improved assemblability by attaching components in a single step, and incorporating anti-backlash gears for reduced sound and improved positional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the motor and light shield bases are separately attached to the base plate, then the assembly process allows for separate component installation, but the work efficiency is reduced and the number of assembly steps increases
Solution Approach 1:
The patent integrates the motor and light shield bases into a single integrated unit that is attached to the base plate as one component rather than separate parts. This merging of components reduces the number of assembly steps and improves work efficiency while maintaining the functional separation needed for operation.
2Device complexity
If the gears are exposed without a cover member, then the structure is simpler and easier to manufacture, but dust adhesion on the gears increases which affects reliability
Solution Approach 1:
The patent introduces a cover member that encloses the gears to protect them from dust adhesion. This thin shell structure maintains relative structural simplicity while significantly improving gear operation reliability by preventing dust accumulation that would hinder gear movement.
3Device complexity
If the gears are exposed without a cover member, then the structure is simpler, but the noise generated during gear rotation increases
Solution Approach 1:
The cover member acts as an acoustic barrier that encloses the gears, reducing the noise generated during rotation. This thin shell structure effectively dampens mechanical noise while maintaining the overall structural simplicity of the device.
4Adaptability or versatility
If multiple components are attached separately to the base plate, then each component can be independently manufactured and replaced, but the number of assembly steps increases and assemblability deteriorates
Solution Approach 1:
The patent combines the motor and light shield bases into an integrated unit that maintains functional independence while improving assemblability. This integrated unit can be manufactured as a single component or pre-assembled module, reducing the number of attachment steps to the base plate while preserving the ability to replace the entire unit if needed.
Data Source
AI summary
A light adjuster includes: a first light shield and a second light shield disposed across a central axis of an emitted light beam; a drive section; a movement mechanism configured to move the first light shield and the second light shield using a driving force; a board; and a cover member combined with the board, in which the movement mechanism includes: a pinion gear; and a first gear and a second gear configured to be rotated in conjunction with a rotation of the pinion gear, the first light shield is attached to the first gear, the second light shield is attached to the second gear, and the cover member supports the first gear and the second gear so that the first gear and the second gear are rotatable, and is combined with the board to cover the pinion gear, the first gear and the second gear.