Resilient Lid Design for Projection Display Optical Tolerance
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Solution Overview
Problem
Conventional projection type image display apparatuses require additional resilient elements to absorb dimensional tolerances of optical elements, leading to increased manufacturing steps and costs due to the use of heat-resistive non-shrinkable resins with little elasticity.
Innovation Solution
The apparatus incorporates an optical system storage with a high-temperature region and a low-temperature region, using a resilient metal lid and a resilient resin lid respectively, to absorb dimensional tolerances without additional parts, allowing precise fixation of optical elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If heat-resistive non-shrinkable resin is used to accommodate the optical system, then the optical elements can be firmly fixed at precise positions, but the resin has little elasticity and cannot absorb dimensional tolerances of the optical elements
Solution Approach 1:
The lid is designed with different materials in different regions: the first lid portion near the light source is made of resilient metal to absorb dimensional tolerances, while the second lid portion farther from the light source is made of heat-resistive resin to maintain precise positions. This local differentiation allows each region to perform its specific function optimally.
Solution Approach 2:
The lid is constructed as a composite structure combining resilient metal and heat-resistive resin materials. This composite design integrates the elasticity needed to absorb dimensional tolerances with the heat resistance and dimensional stability required for precise optical element fixation.
2Adaptability or versatility
If additional resilient elements are used to fix optical elements, then dimensional tolerances can be absorbed, but the number of parts increases and manufacturing steps and cost increase
Solution Approach 1:
The resilient metal lid portion integrates both the covering function and the dimensional tolerance absorption function into a single component. This eliminates the need for separate resilient elements that would otherwise be required to fix optical elements, thereby reducing the number of parts and simplifying manufacturing.
3Temperature
If heat-resistive resin is used for the lid, then the optical system can be protected from heat, but the cost increases due to the costly resin material
Solution Approach 1:
Heat-resistive resin is applied only to the second lid portion that is farther from the light source and does not require direct heat resistance. The first lid portion near the light source is made of resilient metal, which is more cost-effective and does not require expensive heat-resistive materials, thereby reducing overall manufacturing cost while maintaining necessary heat protection where required.
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 solution reduces manufacturing steps and costs by eliminating the need for costly heat-resistive resin and additional parts, while ensuring precise fixation of optical elements.
Implementation Method 1
a resilient metal lid... to absorb the dimensional tolerances of the optical elements
Implementation Method 2
a resilient resin lid... to absorb the dimensional tolerances of the optical elements
Data Source
AI summary
Elements of an optical system (12) of a projection type image display apparatus are stored in an optical system storage (46) having an upper opening in such a way that the optical element to be arranged close to a light source is fitted in the frame provided in the high-temperature region of the optical system storage (46) close to the light source, while the rest of the optical elements are respectively fitted in the frames in the low-temperature region of the optical system storage (46) remote from the light source. The upper opening in the high-temperature region is covered, in the low-temperature region, with a resilient metal lid (471), and, in the low-temperature region, covered with a resilient resin lid (472). Portions of these lids are partially cut into spring-like narrow strips having tips configured to firmly and accurately hold the lenses fitted in the respective frames, whereby the dimensional tolerances of the optical elements and the frames can be absorbed solely by the lids without resorting to any other parts.