Stacked Optical Layers for Compact Projector Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional projectors are not compact enough to be integrated into portable devices like smartphones and tablets for dynamic pattern generation, such as 3D scanning, due to their size and complexity.
Innovation Solution
A projector design featuring a stacked arrangement of semiconductor die with a digital micromirror device and multiple integral optical layers, including diffractive optical elements and lenses, which are optically aligned and attached using an adhesive, forming a compact optical path for light to pass through and reflect off the micromirror device, ensuring efficient light utilization and minimal loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional projector designs are used, then projection functionality is achieved, but the device size is too large for integration into portable devices
Solution Approach 1:
The patent transitions from a planar arrangement of optical components to a three-dimensional stacked configuration. Multiple optical layers (illumination layer, modulation layer, projection layer) are vertically stacked to achieve compact form factor while maintaining optical functionality, enabling integration into portable devices with limited space
Solution Approach 2:
The patent implements nesting by placing multiple optical layers within each other's optical paths in a stacked configuration. The illumination layer, modulation layer, and projection layer are nested vertically, with each layer contributing to the overall projection function while minimizing the total device volume
2Device complexity
If multiple separate optical components are used, then optical functionality is achieved, but device complexity increases
Solution Approach 1:
The patent merges multiple optical components into integrated optical layers. Each layer combines multiple functions (e.g., the illumination layer integrates light source, collimation optics, and illumination distribution), reducing the total number of discrete components while improving alignment reliability through the stacked configuration
3Volume of moving object
If light path length is increased, then projection quality is improved, but device volume increases
Solution Approach 1:
The patent extends the optical path in the vertical dimension through stacked layers rather than horizontally. This allows sufficient optical path length for quality projection while maintaining a compact horizontal footprint suitable for portable devices
Solution Approach 2:
The patent optimizes optical parameters at each layer to maintain projection quality within a compact volume. This includes optimizing lens focal lengths, aperture sizes, and layer spacing to achieve high coupling efficiency and minimal light loss despite the reduced overall device size
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 compact projector design enables the generation of monochromatic patterns for 3D scanning within portable devices, achieving high coupling efficiency and minimal light loss while being small enough to be integrated into smartphones and tablets.
Implementation Method 1
The first integral optical layer includes a first optical lens and a first diffractive optical element. A second integral optical layer is attached to the first integral optical layer. The second integral optical layer includes an aperture stop and a second diffractive optical element.
Implementation Method 2
The first integral optical layer includes a first optical lens and a first diffractive optical element. The third integral optical layer includes a second optical lens and a mount for a light source. Light to: pass through the second diffractive optical element and the first diffractive optical element; reflect off the digital micromirror device; and pass through the first optical lens, the aperture stop and the second lens.
Implementation Method 3
The semiconductor die including a digital micromirror device. Light to: pass through the second diffractive optical element and the first diffractive optical element; reflect off the digital micromirror device; and pass through the first optical lens, the aperture stop and the second lens.
Data Source
AI summary
A projector includes a semiconductor die including a digital micromirror device; and a first integral optical layer attached to the semiconductor die. The first integral optical layer includes a first optical lens and a first diffractive optical element. A second integral optical layer is attached to the first integral optical layer. The second integral optical layer includes an aperture stop and a second diffractive optical element. A third integral optical layer is attached to the second integral optical layer. The third integral optical layer includes a second optical lens and a light source mount. The semiconductor die, the first integral optical layer, the second integral optical layer and the third integral optical layer are stacked to form an optical path through the first and second diffractive optical elements, reflect off the digital micromirror device, and pass through the first optical lens, the aperture stop and the second lens.