Projector Light Source Module Using Optical Fibers

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Solution Overview

Problem

Conventional projectors face increased manufacturing costs and design complexity due to the need for larger combiners and greater bending angles as the number of laser diodes increases, which affects the uniformity and homogeneity of the illumination beam on the phosphor wheel.

Innovation Solution

The use of optical fibers to guide illumination sub-beams from multiple light sources to a light integration rod, eliminating the need for a large combiner and ensuring a homogeneous illumination beam is achieved by the integration rod's homogenization effect, thereby reducing manufacturing costs and design complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If the number of laser diodes is increased to increase brightness, then the brightness of the projected image is improved, but the size of the combiner increases and the design difficulty increases

Engineering Contradiction:

Improvebrightness of projected imageVSAvoiddesign difficulty of light source module

Core Design Contradiction:

Illumination intensityVSDevice complexity

Solution Approach 1:

The patent segments the light gathering function by replacing the conventional combiner with multiple independent optical fibers. Each optical fiber individually collects light from corresponding laser diodes and transports it to the integrating rod, eliminating the need for a large combiner and reducing design complexity while maintaining the ability to handle multiple light sources

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces optical fibers as intermediary elements between the laser diodes and the integrating rod. These optical fibers serve as mediators that transport light from multiple distributed sources to a centralized location without requiring direct optical coupling or a large combiner structure

Inventive Principle:

Principle #24Intermediary (Mediator)

2Illumination intensity

If the number of laser diodes is increased to increase brightness, then the brightness of the projected image is improved, but the manufacturing cost increases

Engineering Contradiction:

Improvebrightness of projected imageVSAvoidmanufacturing cost of light source module

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

The patent divides the light transport system into independent optical fiber channels, each handling light from specific laser diodes. This segmentation allows for modular assembly and reduces the need for complex precision alignment mechanisms, thereby lowering manufacturing costs while supporting multiple light sources for increased brightness

Inventive Principle:

Principle #1Segmentation

3Quantity of substance

If a large combiner is used to concentrate light from multiple laser diodes, then the light concentration is improved, but the bending angle of light beams increases and design difficulty increases

Engineering Contradiction:

Improvelight concentrationVSAvoiddesign difficulty of light path

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The patent uses optical fibers as intermediary light transport channels that maintain consistent light paths from each laser diode to the integrating rod. This eliminates the need for large bending angles associated with large combiners, as each optical fiber independently guides light with minimal deviation, simplifying the overall light path design

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This approach reduces manufacturing costs and design difficulties while providing a uniform illumination beam to the phosphor wheel, enhancing the projector's projection effect and preventing phosphor wheel burning from overly concentrated beams.

Implementation Method 1

Each of the illumination sub-beams is transmitted to the light input end by the corresponding optical fiber

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Implementation Method 2

the light integration rod has a light input end and a light output end... passes through the light integration rod and emits out of the light output end, so as to form a first illumination beam

Methodology Applied

Scientific EffectLight scattering: Scattering

Implementation Method 3

a portion of the blue light is converted into red light and green light by the phosphor wheel 622

Methodology Applied

Scientific EffectPhotoluminescence: Photoluminescence

Data Source

PatentUS9651854B2Projector

Publication Date: 2017.05.16 CORETRONIC CORPORATION

AI summary

A projector includes a light source module, an optical engine, a light valve and a projecting lens. The light source module includes light sources, optical fibers and a light integration rod. Each of the light sources provides an illumination sub-beam. Each of the illumination sub-beams transmits to the light integration rod through the corresponding optical fiber, and passes through the light integration rod and emits out to form a first illumination beam. The optical engine includes a phosphor wheel located at a transmission path of the first illumination beam and converting the first illumination beam into a second illumination beam. The light valve is located at a transmission path of the second illumination beam and converts the second illumination beam into an image beam. The projecting lens is located at a transmission path of the image beam and projects the image beam out of the projector.