Single-Plate Convergence Mechanism for Stable Projector Alignment
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Solution Overview
Problem
Traditional convergence mechanisms for three chip DMD light engines are mechanically complex, space-consuming, expensive, and prone to misalignment due to environmental factors, compromising image quality and requiring excessive adjustment efforts.
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, eliminating the need for multiple moving parts and reducing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional mechanical convergence mechanisms with multiple moving components are used, then a range of adjustment is provided, but the device complexity increases and reliability decreases due to susceptibility to drifting out of alignment
Solution Approach 1:
The patent merges multiple adjustment functions into a single rigid plate component that provides both X and Y axis convergence adjustment. The plate includes multiple adjustment features that can independently adjust the position of optical components in perpendicular directions, eliminating the need for separate mechanical assemblies for each adjustment direction.
Solution Approach 2:
The single rigid plate serves multiple functions: it provides structural support for mounting optical components, enables convergence adjustment in both X and Y directions through integrated adjustment features, and maintains precise alignment stability. This multi-functional design replaces traditional multi-component mechanisms while reducing overall device complexity.
2Adaptability or versatility
If traditional mechanical convergence mechanisms are used, then adjustment capability is provided, but the area occupied on PCB increases
Solution Approach 1:
The patent combines multiple adjustment mechanisms into a single integrated rigid plate structure that mounts directly to the PCB. By consolidating X-axis and Y-axis adjustment features into one component, the overall footprint on the PCB is reduced compared to traditional separate mechanical assemblies for each adjustment direction.
Solution Approach 2:
The rigid plate is designed as a thin, planar component with integrated adjustment features that minimizes vertical profile and horizontal footprint. The plate's streamlined design allows it to occupy minimal PCB space while providing full convergence adjustment capability through its integrated adjustment screws and mounting features.
3Adaptability or versatility
If traditional mechanical convergence mechanisms are used, then adjustment range is provided, but manufacturing cost increases
Solution Approach 1:
The patent consolidates multiple adjustment mechanisms into a single rigid plate that can be manufactured as one piece using standard machining or molding processes. This integration eliminates the need to manufacture, assemble, and align multiple separate mechanical components, thereby reducing manufacturing complexity and cost while maintaining full X-Y convergence adjustment capability.
Solution Approach 2:
The rigid plate is designed with distinct, modular adjustment features for X-axis and Y-axis convergence that can be independently adjusted. This segmentation of adjustment functions within a single component allows for simplified manufacturing and assembly compared to traditional multi-component mechanisms, reducing both production cost and assembly time.
4Adaptability or versatility
If electronic convergence with sub-pixel dithering is used, then convergence adjustment is provided, but image quality deteriorates
Solution Approach 1:
The patent replaces electronic convergence methods with a mechanical adjustment system using a rigid plate with physical adjustment features. This mechanical approach allows for precise, stable alignment of optical components that maintains image quality by avoiding the image softening effects associated with electronic dithering methods, while still providing full convergence adjustment capability.
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, stable alignment within a limited adjustment range, minimizing manufacturing defects and assembly time while maintaining image quality, and is resistant to drifting out of alignment.
Implementation Method 1
a pair of slot spring mechanisms in the plate... causing the spring mechanisms to deform in the plane of the plate
Data Source
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 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 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.