Projector Light Modulator Plate Mechanism for Precise Convergence
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Solution Overview
Problem
Existing three chip DMD light engines for projectors require complex mechanical convergence mechanisms that are space-consuming, expensive, prone to misalignment, and compromise image quality due to environmental factors.
Innovation Solution
A single component convergence mechanism using a laterally deformable plate with adjustable spring mechanisms allows precise alignment of light modulators in two perpendicular directions, reducing mechanical complexity and susceptibility to misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mechanical convergence mechanisms are used, then fine X-Y optical adjustment of DMD positions is achieved, but device complexity increases and space consumption increases
Solution Approach 1:
The patent combines multiple adjustment functions (X-position, Y-position, and rotation) into a single convergence mechanism assembly that integrates multiple adjustment screws working together on a common platform, reducing the number of separate mechanisms needed while maintaining precise alignment capability
Solution Approach 2:
The convergence mechanism is designed to perform multiple functions simultaneously - adjusting X-position, Y-position, and rotational alignment of the DMD chip using a unified mechanical structure, making the mechanism versatile and reducing overall system complexity
2Manufacturing precision
If traditional mechanical convergence mechanisms are used, then fine X-Y optical adjustment of DMD positions is achieved, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple adjustment functions (X-position, Y-position, and rotation) into a single convergence mechanism assembly that integrates multiple adjustment screws working together on a common platform, reducing the number of separate mechanisms needed while maintaining precise alignment capability
Solution Approach 2:
The mechanism allows for adjustable convergence parameters through threaded screws that enable precise positioning of the DMD chip in X and Y directions and rotational adjustment, facilitating cost-effective manufacturing through standardized threaded components
3Adaptability or versatility
If traditional mechanical convergence mechanisms are used, then adjustment range is provided, but alignment stability decreases due to environmental factors
Solution Approach 1:
The mechanism allows for adjustable convergence parameters through threaded screws that enable precise positioning of the DMD chip in X and Y directions and rotational adjustment, facilitating cost-effective manufacturing through standardized threaded components
Solution Approach 2:
The patent replaces complex multi-component mechanical mechanisms with a simplified screw-based adjustment system that uses elastic deformation of a single component to achieve convergence, reducing mechanical complexity and potential failure points
4Manufacturing precision
If electronic convergence with sub-pixel dithering is used, then misalignment is masked, but image quality decreases
Solution Approach 1:
The patent replaces complex multi-component mechanical mechanisms with a simplified screw-based adjustment system that uses elastic deformation of a single component to achieve convergence, reducing mechanical complexity and potential failure points
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 mechanism provides robust, cost-effective alignment with minimal drift, ensuring pixel alignment within acceptable thresholds without compromising image quality.
Implementation Method 1
the pressure causing the spring mechanisms to deform in the plane of the plate, thereby moving a displaceable region of the plate
Data Source
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AI summary
A single component convergence mechanism for a light modulator of a projector is provided. The single component convergence mechanism includes: a plate; a light-modulator-mounting position at the plate; a pair of slot spring mechanisms in the plate, the pair of slot spring mechanisms on opposite sides of the light-modulator-mounting position; and a pair of connecting slots (1116) in the plate joining the pair of slot spring mechanisms. A region formed by the pair of slot spring mechanisms and the pair of connecting slots (1116) is laterally displaceable within the plate via force applied to on a spring mechanism of the pair of slot spring mechanisms, the light-modulator-mounting position located at the region. The pair of slot spring mechanisms are connected to the region to a remainder of the plate.