Sheet Metal Support Stand for Ultra-Short-Throw Projectors
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Solution Overview
Problem
Ultra-short-throw projectors face high manufacturing costs due to the need for precise optical components and casting members, leading to reduced market competitiveness.
Innovation Solution
A support stand made of sheet metal, specifically galvanized steel, with a base having a "" or inverted "U" shape, combined with adjusting units to maintain structural rigidity and precision, while allowing for cost-effective manufacturing and adjustment of optical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If casting members with high precision are used to carry and fix optical components, then optical quality and projection path accuracy are improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent changes the material parameter from traditional precision casting to sheet metal (such as cold-rolled sheet metal or aluminum alloy sheet metal), and changes the manufacturing process parameters from casting to cutting, bending, punching and extending. This allows achieving required precision through process optimization rather than expensive casting, thereby reducing manufacturing cost while maintaining optical component positioning accuracy
Solution Approach 2:
The patent replaces expensive precision casting members with cheaper sheet metal structures. The sheet metal support stand achieves functional equivalence through optimized geometry and structure, eliminating the need for costly precision casting processes while maintaining adequate precision for optical component mounting
2Ease of manufacture
If sheet metal is used instead of casting members, then manufacturing cost is reduced, but structural rigidity and precision may deteriorate
Solution Approach 1:
The patent employs curved and folded sheet metal structures (such as bent plates, folded sections, and arched supports) to achieve structural rigidity. The curvature and folding create geometric stiffness that compensates for the inherent flexibility of sheet metal, allowing the structure to maintain precision while being manufactured from inexpensive sheet material
Solution Approach 2:
The patent transitions from planar sheet metal to three-dimensional structures through cutting, bending and folding. By creating spatial configurations with multiple dimensions (vertical supports, horizontal cross-bracing, angled reinforcements), the structure achieves rigidity equivalent to solid casting members while retaining the cost advantages of sheet metal fabrication
3Device complexity
If fixed support structure is used, then manufacturing simplicity is maintained, but adaptability for different optical configurations is reduced
Solution Approach 1:
The patent incorporates adjustable elements into the sheet metal support stand, such as movable mounting positions, adjustable-angle brackets, and reconfigurable support arms. These dynamic features allow the structure to be adapted to different optical component arrangements and projection requirements while maintaining overall structural simplicity and low manufacturing cost
Data Source
AI summary
A support stand made of sheet metal is cooperated with an optical module and a reflective module. The support stand includes a base and a back frame. The optical module is disposed on the base. To enhance its structural rigidity, the base substantially has a “” or inverted “U” shape as viewed from an optical axis. The back frame is connected with the base, and the reflective module is disposed on the back frame. An optical apparatus with the above support stand is also disclosed.