CN113009750A

CN113009750A - Projection optical machine and manufacturing method thereof

Info

Publication number: CN113009750A
Application number: CN202110180811.4A
Authority: CN
Inventors: 侯风超; 刘德安; 饶轶
Original assignee: Goertek Optical Technology Co Ltd
Current assignee: Goertek Optical Technology Co Ltd
Priority date: 2021-02-07
Filing date: 2021-02-07
Publication date: 2021-06-22

Abstract

The invention discloses a projection optical machine and a manufacturing method thereof, wherein the projection optical machine comprises a shell, an illuminating component and an imaging component, wherein the shell is of a nano injection molding structure, and an accommodating cavity is formed in the shell; the lighting assembly is arranged in the accommodating cavity and emits emergent light; the imaging assembly is arranged in the accommodating cavity and is positioned on a light path of emergent light of the illuminating assembly. The casing of the projection optical machine in the technical scheme of the invention has high structural strength and good high-temperature dimensional stability, and then the problems of dark bands and temperature drift of the projection optical machine are solved.

Description

Projection optical machine and manufacturing method thereof

Technical Field

The invention relates to the technical field of projection optical machines, in particular to a projection optical machine and a manufacturing method thereof.

Background

The main structure of the projection optical-mechanical system comprises an illumination system, an imaging optical path, a main body frame, an upper cover and other auxiliary components, wherein the illumination system mainly comprises an LED light source, a collimating lens, a filter, a beam combining and homogenizing system and the like, and the imaging optical path mainly comprises an image source, a prism, a projection lens and the like. At present, a high-end projection light machine pursues compactness, high light efficiency brightness and high imaging quality, so the requirement on the dimensional stability of a main body frame at high temperature is more strict, from the viewpoint of dimensional accuracy, the dimensional variation of the main body frame, which is larger than 0.02mm and generated at high temperature, may obviously change the optical imaging result, and an illumination system and an imaging light path which are mainly used in the projection light machine are both arranged on the main body frame, so the requirement on the dimensional stability of the main body frame in the forming process is particularly high.

At present, the main body frame of a projection optical-mechanical system deforms in a micro size at a high temperature, so that light spots of an illumination light path can not uniformly irradiate the surface of an image source to form a dark zone; secondly, the image source or the prism is inclined, so that the resolving power is poor; and thirdly, the main body deforms in the using process, so that the problems of connection failure of electronic parts such as an image source and the like, or defocusing failure of an optical part and the like can be caused.

Disclosure of Invention

The invention mainly aims to provide a projection light machine, aiming at improving the dimensional stability of a main body frame.

In order to achieve the above object, the invention provides a projection light engine comprising:

the shell is of a nano injection molding structure, and an accommodating cavity is formed in the shell;

the illuminating assembly is arranged in the accommodating cavity and emits emergent light; and

and the imaging assembly is arranged in the accommodating cavity and is positioned on the light path of emergent light of the illuminating assembly.

In an optional embodiment, the housing includes a bottom plate, a side plate, and a top plate, the bottom plate, the side plate, and the top plate enclose to form the accommodating cavity, the bottom plate is a nano injection molding structure, and the illumination assembly is disposed near the bottom plate.

In an alternative embodiment, the base plate comprises an integrally formed metal part and a plastic part;

the metal part is made of stainless steel; and/or the presence of a gas in the gas,

the plastic part is made of at least one of polyphenylene sulfide, polyetherimide, polycarbonate and polybutylene terephthalate.

In an alternative embodiment, the plastic part and the side plate are of an integrally formed structure.

In an alternative embodiment, the top plate and/or the side plate are of a nano injection molding structure, and the imaging assembly is arranged close to the top plate.

In an optional embodiment, the illumination assembly includes a light source, a light combining member and a light uniformizing member, light emitted from the light source is emitted to the light uniformizing member after passing through the light combining member, and light passing through the light uniformizing member is the emergent light.

In an optional embodiment, the imaging component includes a projection chip and a projection lens, and the projection chip receives and reflects the emergent light, so that the projection lens receives the reflected light.

The invention further provides a manufacturing method of the projection light machine, the projection light machine comprises a shell, and an illumination assembly and an imaging assembly which are arranged in the shell, and the manufacturing method of the projection light machine comprises the following steps:

preparing the shell by adopting a nano injection molding process;

the illumination assembly and the imaging assembly are sequentially mounted within the housing.

In an optional embodiment, the step of preparing the housing by using a nano injection molding process specifically includes:

providing a metal substrate;

corroding the metal substrate to form micro-nano holes, and performing surface treatment on the micro-nano holes;

and a plastic part is injected at the micro-nano hole in a nano mode so as to form a shell with an accommodating cavity in a surrounding mode with the corroded metal base body.

In an optional embodiment, after the step of using the template to mold the plastic part at the micro-nano hole in a nano manner to form the housing having the accommodating cavity in an enclosing manner with the corroded metal substrate, the method further includes:

and carrying out electrolytic polishing treatment on the shell.

The projection light machine comprises a shell, and an illumination assembly and an imaging assembly which are arranged on the shell, wherein the shell provides a supporting foundation and a protecting foundation for the illumination assembly and the imaging assembly, so that emergent light of the illumination assembly can be emitted to the imaging assembly along a specified light path route to perform image projection. The shell is of a nano injection molding structure, namely the shell structure formed by using a nano injection molding process, and the nano injection molding structure has higher structural strength compared with a conventional injection molding body, so that the nano injection molding structure is not easy to deform, and the product yield can be effectively improved in the processing process, so that the structural stability of the shell is good; and the metal part that nanometer injection structure includes can also improve the heat dispersion of casing for the heat that inside produced distributes away in time, can guarantee then that projection light machine's lighting assembly can not produce the dark band, and the formation of image quality is good, and can obviously improve the temperature drift effect.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the structures shown in the drawings without creative efforts.

FIG. 1 is a schematic structural diagram of a projection optical system according to an embodiment of the present invention;

FIG. 2 is a schematic diagram of a base plate of the optical projection engine shown in FIG. 1;

FIG. 3 is a schematic diagram of the optical projector shown in FIG. 1;

FIG. 4 is a flowchart of a method for manufacturing a projection light engine according to an embodiment of the present invention;

FIG. 5 is a flowchart of another embodiment of a method for manufacturing a light engine according to the present invention;

FIG. 6 is a flowchart illustrating a method for manufacturing a light engine according to another embodiment of the present invention.

The reference numbers illustrate:

100	projection light machine	30	Lighting assembly
				10	Shell body	31	Light source
11	Top board	33	Light combining piece
				13	Base plate	35	Uniform light part
131	Metal part	50	Imaging assembly
				133	Plastic part	51	Projection chip
15	Side plate	53	Projection lens

The implementation, functional features and advantages of the objects of the present invention will be further explained with reference to the accompanying drawings.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

It should be noted that all the directional indicators (such as up, down, left, right, front, and rear … …) in the embodiment of the present invention are only used to explain the relative position relationship between the components, the movement situation, etc. in a specific posture (as shown in the drawing), and if the specific posture is changed, the directional indicator is changed accordingly.

In the present invention, unless otherwise expressly stated or limited, the terms "connected," "secured," and the like are to be construed broadly, and for example, "secured" may be a fixed connection, a removable connection, or an integral part; can be mechanically or electrically connected; they may be directly connected or indirectly connected through intervening media, or they may be connected internally or in any other suitable relationship, unless expressly stated otherwise. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.

In addition, the descriptions related to "first", "second", etc. in the present invention are only for descriptive purposes and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In addition, technical solutions between various embodiments may be combined with each other, but must be realized by a person skilled in the art, and when the technical solutions are contradictory or cannot be realized, such a combination should not be considered to exist, and is not within the protection scope of the present invention.

The invention provides a projection optical engine 100, belonging to high-end optical engine products.

Referring to fig. 1 to fig. 3, in an embodiment of the invention, a projection optical apparatus 100 includes:

the shell 10 is of a nano injection molding structure, and an accommodating cavity is formed in the shell 10;

the lighting assembly 30 is arranged in the accommodating cavity, and emergent light is emitted out of the illuminating assembly 30; and

and the imaging assembly 50 is arranged in the accommodating cavity and is positioned on a light path of emergent light of the illumination assembly 30.

In this embodiment, the optical projection engine 100 includes a housing 10, and an illumination assembly 30 and an imaging assembly 50 disposed inside the housing 10, and the emergent light from the illumination assembly 30 is emitted to the imaging assembly 50 to project an image, and the final projection is projected by using a screen, so as to facilitate viewing.

Specifically, the shape of the housing 10 may be a rectangular parallelepiped, a cube, a sphere or other irregular shapes, which is not limited herein. The housing 10 may be a frame structure, and is formed with an accommodating cavity, which may provide an installation space. Of course, other fixing structures can be arranged in the fixing structure, so that the fixing of each part is convenient. Nano injection Molding refers to Nano Molding Technology (NMT), which is a process of combining metal and plastic by Nano Technology, i.e., after Nano treatment is performed on the surface of metal, plastic is directly injected and molded on the surface of metal, so that metal and plastic can be integrally molded. Here, the case 10 is a nano injection molding structure, that is, a structure manufactured by a nano injection molding process, and thus includes the metal portion 131 and the plastic portion 133, and here, the ratio and the position of the metal portion 131 and the plastic portion 133 are not limited, and may be set as needed.

It can be understood that, in an embodiment, the illumination assembly 30 includes a light source 31, a light combining member 33, and a light uniformizing member 35, light emitted from the light source 31 passes through the light combining member 33 and then is directed to the light uniformizing member 35, and light passing through the light uniformizing member 35 is the outgoing light. The light source 31 may include a plurality of light-emitting substrates, a mounting hole is formed in the housing 10, and the light-emitting substrates are mounted in the mounting hole, so that light emitted by the light-emitting substrates can be directed toward the inside of the accommodating cavity, each light-emitting substrate can only emit one color light, but each light-emitting substrate can include a plurality of light-emitting devices. Because blue, red and green are basic colors which can not be decomposed any more, and the three colors can be mixed to form various colors, the light source 31 can be provided with three light-emitting substrates which are positioned at different directions and respectively emit blue light, red light and green light, then any needed colored light can be obtained through the light combining piece 33, and the light emitted by the light combining piece 33 is emitted to the light homogenizing piece 35, so that the distribution of the emergent light is more uniform, and the imaging effect is improved. Of course, the light source 31 may be in other forms, for example, blue, red and green light emitting diodes are directly mounted on the inner wall of the housing 10, which is not limited herein, and only needs to provide the required emergent light. In addition, lighting component 30 can also include collimating mirror and filter etc. and the collimating mirror can make to diverge the light path and become parallel light path, and the filter can improve the contrast that light source 31 sent light, improves the luminous effect of lighting component 30's emergent light.

Of course, in an embodiment, the imaging assembly 50 includes a projection chip 51 and a projection lens 53, the projection chip 51 receives and reflects the outgoing light, so that the projection lens 53 receives the reflected light. The projection chip 51 is the most core Device of the projector 100, and here, the projection chip 51 may be selected as a DMD (Digital Micromirror Device), and the working principle thereof is to reflect the required light by means of a Micromirror Device, and simultaneously, to absorb the unnecessary light by means of a light absorber to realize the projection of an image, and the illumination direction thereof is realized by means of an electrostatic effect by controlling the angle of a Micromirror, and finally, the reflected light is directed to the projection lens 53, thereby realizing the projection of an image. Of course, the illumination assembly 30 and the imaging assembly 50 are only used for facilitating understanding of the operation process of the light engine 100, and are not used to limit the scope of the present invention.

The optical projector 100 according to the technical solution of the present invention includes a housing 10, and an illumination assembly 30 and an imaging assembly 50 disposed on the housing 10, where the housing 10 provides a supporting base and a protecting base for the illumination assembly 30 and the imaging assembly 50, so that emergent light from the illumination assembly 30 can be emitted to the imaging assembly 50 along a specified light path to perform image projection. Here, the housing 10 is a nano injection molding structure, that is, the housing 10 structure formed by using a nano injection molding process has higher structural strength compared with a conventional injection molded body, so that the housing 10 formed by nano injection molding is used for structural reinforcement, so that the deformation is not easy to occur, the product yield can be effectively improved in the processing process, and the structural stability of the housing 10 is good; and the metal part 131 that the nanometer injection structure includes can also improve the heat dispersion of casing 10 for the heat that produces inside distributes away in time, can guarantee then that the illumination component 30 of projection light machine 100 can not produce the dark band, and the formation of image quality of formation of image subassembly 50 is good, and can obviously improve the temperature drift problem that arouses because of the high temperature.

In an alternative embodiment, the housing 10 includes a bottom plate 13, a side plate 15, and a top plate 11, the bottom plate 13, the side plate 15, and the top plate 11 enclose the accommodating cavity, the bottom plate 13 is a nano injection molding structure, and the lighting assembly 30 is disposed on the bottom plate 13.

In this embodiment, the housing 10 is a square structure, that is, includes a bottom plate 13, four side plates 15 and a top plate 11, and the four side plates 15 jointly enclose to form an accommodating cavity. Because the light source 31 in the lighting assembly 30 emits light, the generated heat energy is more, when the lighting assembly 30 is arranged on the bottom plate 13, the bottom plate 13 is designed to be of a nano injection molding structure, namely, the bottom plate 13 is partially made of metal materials and partially made of plastic materials, and the two are integrally molded through a nano injection molding process, so that the stability of the molding size is ensured, the structural strength of the bottom plate 13 can be enhanced, the deformation of the bottom plate 13 due to external force is effectively prevented, the matching precision can be improved in the subsequent installation process, and the problem of dark bands of the lighting assembly 30 is effectively solved. Meanwhile, the metal material part of the bottom plate 13 is provided with the light source 31, and the heat dissipation performance and the heat resistance of the metal material are obviously higher than those of plastic, so that heat generated by the light source 31 can be further conveniently and timely dissipated, the temperature in the accommodating cavity of the shell 10 is not too high, the working performance of each component and the structural stability of the shell 10 are ensured, the problems that the optical part is out of focus and fails due to too high temperature and the like are solved, and the product stability of the projection optical machine 100 is improved.

Of course, in other embodiments, the illumination assembly 30 may be disposed on the side plate 15, and the emitted light is emitted close to the bottom plate 13.

In an alternative embodiment, the base plate 13 includes an integrally formed metal portion 131 and plastic portion 133;

the metal part 131 is made of stainless steel; and/or the presence of a gas in the gas,

the plastic part 133 is made of at least one material selected from the group consisting of polyphenylene sulfide, polyetherimide, polycarbonate, and polybutylene terephthalate.

In this embodiment, the bottom plate 13 includes a metal portion 131 and a plastic portion 133, and the material of the metal portion 131 may be selected from conventional 304 stainless steel sheet. Of course, in other embodiments, other metal materials, such as magnesium, etc., may be selected as desired. Meanwhile, the plastic part 133 is made of polyphenylene sulfide (PPS), Polyetherimide (PEI), Polycarbonate (PC) reinforced with filler, or Polybutylene terephthalate (PBT), and can resist the plating line, thereby significantly improving the structural strength and dimensional stability of the bottom plate 13.

In an alternative embodiment, the plastic portion 133 is integrally formed with the side panel 15.

In this embodiment, for further convenient processing, when curb plate 15 and roof 11 were the plastics material, can accomplish the processing of the metal part 131 of bottom plate 13 earlier, then through the integrative injection moulding of plastic part 133 and curb plate 15 of template with bottom plate 13, further improve the structural stability and the intensity of casing 10, also can simplify manufacturing procedure simultaneously, save the equipment in later stage, improve production efficiency.

Of course, in other embodiments, the bottom plate 13, the side plate 15 and the top plate 11 may be connected in an assembled manner.

In an alternative embodiment, the top plate 11 and/or the side plate 15 are made of a nano-molded structure, and the imaging assembly 50 is disposed adjacent to the top plate 11.

In this embodiment, since the imaging module 50 includes high-precision components such as the projection chip 51, in order to ensure the mounting precision of the components such as the projection chip 51, the top plate 11 and/or the side plate 15 for fixing the structures may be configured to be a nano injection structure, so that the yield of the optical projection engine 100 may be improved, and the projection effect may be further ensured. For example, when the imaging assembly 50 is disposed on the top plate 11, the top plate 11 is provided as a nano-molded structure; when the mounting position of the imaging assembly 50 includes the top plate 11 and the side plate 15, the top plate 11 and the side plate 15 are simultaneously set to the nano injection structure.

It is understood that, in order to install the internal components, an opening is required to be opened on the housing 10, and after the installation of the optical elements of the illumination assembly 30 and the imaging assembly 50 is completed, the image source can be installed in the housing 10, and a cover plate or the like for covering the opening is installed. In addition, in order to further improve the overall heat dissipation performance of the optical projection engine 100, a heat dissipation member, such as a heat dissipation sheet or a heat dissipation plate, may be further installed in the casing 10 to further ensure the safety temperature inside the optical projection engine 100, and improve the projection effect

Referring to fig. 1 and fig. 4, the present invention further provides a manufacturing method of a light projector 100, where the light projector 100 includes a housing 10, an illumination module 30 and an imaging module 50 disposed inside the housing 10, and the manufacturing method of the light projector 100 includes:

step S1: preparing the shell 10 by adopting a nano injection molding process;

step S2: the illumination assembly 30 and the imaging assembly 50 are mounted in turn within the housing 10.

In this embodiment, the optical projector 100 includes a housing 10, an illumination assembly 30, and an imaging assembly 50, and the specific structure of the above components can refer to the structure of the above embodiment, which is not described herein again. In step S1, the case 10 is prepared by using a nano injection molding process, so that a nano injection molding structure is formed at a part of the case 10, or the case 10 is a nano injection molding structure as a whole, which has high structural strength and good dimensional stability, and then step S2 is performed, and the illumination assembly 30 and the imaging assembly 50 are installed inside the case 10. The specific fixing position and fixing mode are not limited, and can be adjusted according to the needs. Thus, the projection optical device 100 manufactured by the above process can serve as a structural reinforcement for the housing 10 having the nano injection structure, so that the housing is not easily deformed, the yield of products can be effectively improved in the manufacturing process, and the structural stability is good. Meanwhile, the metal part 131 included in the nano injection structure can also improve the heat dissipation performance of the shell 10, so that the heat generated inside can be timely dissipated, the illumination assembly 30 of the projection light machine 100 can not generate a dark band, the imaging quality of the imaging assembly 50 is good, and the temperature drift problem caused by high temperature can be obviously improved.

Of course, taking the housing 10 as an example of a frame structure, in order to facilitate installation of internal components, an opening needs to be formed in the housing 10, and after the optical elements of the illumination module 30 and the imaging module 50 are mounted, the image source may be installed in the housing 10, and a cover plate or other components for covering the opening may be installed. In addition, in order to further improve the overall heat dissipation performance of the optical projection engine 100, a heat dissipation member, such as a heat dissipation sheet or a heat dissipation plate, may be further installed in the casing 10, so as to further ensure that the inside of the optical projection engine 100 is at a safe temperature, and improve the projection effect.

Referring to fig. 2 and 5, in an alternative embodiment, the step S1 of preparing the housing 10 by using a nano injection molding process specifically includes:

step S11: providing a metal substrate;

step S12: corroding the metal substrate to form micro-nano holes, and performing surface treatment on the micro-nano holes;

step S13: and a plastic part 133 is injected at the micro-nano hole to form a shell 10 with a containing cavity by enclosing with the corroded metal matrix.

The metal matrix in step S11 is a 304 stainless steel sheet, and is first cut into a metal matrix with a suitable size according to the size of the bottom of the desired housing 10, and then the metal matrix is subjected to alkali treatment to be degreased and cleaned, so that the cleanliness is improved, the subsequent processing is facilitated, and the metal matrix is dried. In step S12, the metal substrate may be corroded by chemical corrosion or electrochemical corrosion, for example, the metal substrate is placed in an acid solution to form micro-nano holes, and the micro-nano holes are subjected to surface treatment, for example, cleaned and dried to increase the roughness thereof, thereby enhancing the bonding strength for the subsequent injection molding. In step S13, an injection molding process is performed, that is, a mold plate is arranged to surround the part to be injection molded, and then the plastic part 133 is injection molded into the micro-nano holes, so as to form the required shape of the housing 10. Here, the plastic part 133 is resin.

Referring to fig. 6, in an alternative embodiment, the step S13 of nano-injecting the plastic part 133 at the micro-nano hole by using the template to form the housing 10 with the containing cavity by enclosing with the corroded metal substrate is: then, the method further comprises the following steps:

step S14: the housing 10 is subjected to an electrolytic polishing process.

In this embodiment, since the housing 10 is used in the high-precision projection light engine 100, in order to make the housing 10 meet the required appearance requirement, the housing 10 after injection molding needs to be subjected to electropolishing treatment to improve the surface smoothness, and meanwhile, the corrosion resistance can also be enhanced. Of course, in other embodiments, the surface of the housing 10 may be painted, electroplated or sputtered to achieve the desired appearance.

The above description is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention, and all modifications and equivalents of the present invention, which are made by the contents of the present specification and the accompanying drawings, or directly/indirectly applied to other related technical fields, are included in the scope of the present invention.

Claims

1. A projection light engine, comprising:

2. The light engine of claim 1, wherein the housing comprises a bottom plate, a side plate, and a top plate, the bottom plate, the side plate, and the top plate enclose the receiving cavity, the bottom plate is a nano-injection structure, and the illumination assembly is disposed adjacent to the bottom plate.

3. The light engine of claim 2, wherein the base plate comprises an integrally formed metal portion and plastic portion;

4. The light engine of claim 3, wherein the plastic portion and the side plate are integrally formed.

5. The light engine of claim 2, wherein the top plate and/or the side plate are nano-molded structures and the imaging assembly is disposed proximate to the top plate.

6. The light engine of any of claims 1-5, wherein the illumination assembly comprises a light source, a light combining member, and a light homogenizing member, wherein light emitted from the light source is emitted to the light homogenizing member after passing through the light combining member, and the light passing through the light homogenizing member is the emergent light.

7. The light engine of any of claims 1 to 5, wherein the imaging assembly comprises a projection chip and a projection lens, and the projection chip receives and reflects the emergent light so that the projection lens receives the reflected light.

8. The manufacturing method of the projection light machine is characterized in that the projection light machine comprises a shell, an illumination assembly and an imaging assembly, wherein the illumination assembly and the imaging assembly are arranged in the shell, and the manufacturing method of the projection light machine comprises the following steps:

preparing the shell by adopting a nano injection molding process;

9. The method of claim 8, wherein the step of fabricating the housing using a nano-injection molding process comprises:

providing a metal substrate;

10. The method for manufacturing the projection optical engine according to claim 9, wherein after the step of using the template to perform nano injection molding on the plastic part at the micro-nano hole to form a housing with a containing cavity by enclosing with the corroded metal substrate, the method further comprises:

and carrying out electrolytic polishing treatment on the shell.