Beam Splitting Module with Biasing Member for Mold Release

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Solution Overview

Problem

Conventional beam splitting modules require special materials for zero-parting-angle fabrication, increasing costs and environmental impact due to the use of thermosetting plastics like BMC, which cannot be recycled.

Innovation Solution

A beam splitting module design featuring a supporting wall with a perpendicular first wall surface and a biasing member to secure a beam splitting lens at a 45-degree angle, allowing for the use of normal plastic materials and reducing fabrication costs by enabling a non-zero parting angle during mold release.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the supporting walls and base plate are formed integrally with perpendicular relationship, then the beam splitter can be properly supported, but special materials like BMC must be used which increases fabrication cost

Engineering Contradiction:

Improvesupporting structure stabilityVSAvoidfabrication cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent divides the supporting structure into separate components: the base plate and the supporting walls are no longer formed integrally. Instead, the supporting walls are positioned and secured separately on the base plate, allowing each component to be manufactured independently using conventional materials with standard parting angles.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of making the supporting walls perpendicular to the base plate (zero parting angle), the patent inverts the approach by allowing the supporting walls to be formed with an inclined relationship to the base plate, enabling the use of normal plastic materials that require non-zero parting angles for mold release.

Inventive Principle:

Principle #13The other way round (Inversion)

2Manufacturing precision

If BMC material is used for integral formation, then zero parting angle is achieved, but the material cannot be recycled which increases environmental impact

Engineering Contradiction:

Improveparting angle controlVSAvoidenvironmental impact

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent changes the parting angle parameter from zero (perpendicular relationship) to a non-zero value, enabling the use of recyclable normal plastic materials instead of BMC. This parameter change allows the supporting walls to be formed with an inclined relationship to the base plate, facilitating mold release and material recyclability.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If normal plastic materials are used, then fabrication cost is reduced and recyclability is improved, but the supporting walls cannot be perpendicular to the base plate

Engineering Contradiction:

Improvefabrication costVSAvoidperpendicular relationship

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The patent introduces adjustability into the supporting wall positioning system. The supporting walls can be positioned at different angles relative to the base plate and secured at the desired orientation. This dynamic positioning capability allows the use of normal plastic materials while still achieving the required perpendicular relationship for beam splitter support through adjustable rather than fixed geometric constraints.

Inventive Principle:

Principle #15Dynamics

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 design reduces fabrication costs and environmental impact by allowing the use of normal plastic materials for the beam splitting module and light source system, facilitating a more sustainable manufacturing process.

Implementation Method 1

One light beam traveling along the first direction impinges one side of the beam splitter at a 45-degree angle and passes through the beam splitter to continue traveling along the first direction

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 2

Another light beam traveling along the second direction impinges an opposite side of the beam splitter at a 45-degree angle and is reflected by the beam splitter to travel further along the first direction

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 3

The biasing member is secured to the base plate, and is disposed adjacent to the second lens surface of the beam splitting lens for urging the beam splitting lens toward the supporting wall

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS7688515B2Beam splitting module and a light source system incorporating the same

Publication Date: 2010.03.30 YOUNG OPTICS

AI summary

A beam splitting module is disposed on a base plate of a light source system, and includes a supporting wall, a beam splitting lens, and a biasing member. The supporting wall has a first wall surface, and is disposed on the base plate such that the first wall surface extends perpendicularly from the base plate. The beam splitting lens has a first lens surface disposed adjacent to the first wall surface of the supporting wall, and a second lens surface opposite to the first lens surface. The biasing member is secured to the base plate, and is disposed adjacent to the second lens surface of the beam splitting lens for urging the beam splitting lens toward the supporting wall such that the first lens surface of the beam splitting lens abuts against the first wall surface of the supporting wall.