Conical Reflector Support Using Thin-Walled Slices
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Solution Overview
Problem
Conical reflectors in 360 degrees laser projection apparatuses face challenges in support stability due to environmental temperature effects and difficulty in adjusting perpendicularity, leading to double-image phenomena and linearity issues with traditional support structures like photoplastic square-tapered shells or cylinders.
Innovation Solution
A laser projection module with a conical reflector supported by thin walls, utilizing four thin-walled supporting slices made of rigid materials like carbon steel or carbon fiber, which allows for self-assembly and adjustment to maintain a 360 degrees laser projection line without break lines, using an adjustment mechanism with bolts and an adjustment base for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If photoplastic square-tapered shell or transparent cylinder is used to support the conical reflector, then the conical reflector can be supported, but the cambered surface creates secondary projection causing double-image phenomenon and it is difficult to adjust perpendicularity
Solution Approach 1:
The support structure is segmented into multiple thin-walled slices (typically 3-4 slices) that are distributed around the conical reflector. Each slice independently supports the reflector at specific angular positions, allowing precise alignment without the cumulative errors of a continuous shell structure.
Solution Approach 2:
The thin-walled slices are designed with specific local geometric properties - their inner surfaces are shaped to match the conical reflector's geometry at specific points, while their outer surfaces provide rigid support. This local optimization ensures both support stability and perpendicularity without requiring the entire support structure to be perfectly uniform.
2Reliability
If photoplastic material is used for the support structure, then the conical reflector can be supported, but the material is greatly impacted by temperature causing shape change and influencing linearity
Solution Approach 1:
The material parameter selection focuses on thermal stability rather than just mechanical strength. Metals and glass-ceramics are chosen specifically because their thermal expansion coefficients are low and predictable, allowing the support structure to maintain its geometric parameters (especially perpendicularity) across temperature variations.
Solution Approach 2:
The support structure uses composite construction - thin-walled metal slices mounted on a rigid backbone structure. This composite approach combines the thermal stability of metal with the structural rigidity of the backbone, preventing shape changes that would affect laser linearity while maintaining support stability.
3Reliability
If thick-walled support structure is used for the conical reflector, then the support stability is improved, but the device complexity and size increase
Solution Approach 1:
The support structure uses thin-walled slices (wall thickness much smaller than the reflector diameter) that provide sufficient support through their geometric configuration and rigid material properties rather than through wall thickness. This thin-walled design reduces overall structure size and complexity while maintaining stability.
Solution Approach 2:
The thin-walled slices are designed with adjustable mounting mechanisms that allow dynamic alignment and positioning. This adjustability compensates for the reduced structural mass, enabling precise perpendicularity adjustment and maintaining support stability without requiring thick walls that would increase complexity.
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 solution provides a stable, compact, and precise support for the conical reflector, ensuring reliability and maintaining the linearity of the laser projection, preventing double-image phenomena and enhancing the apparatus's stability across varying temperatures.
Implementation Method 1
the top of the conical mirror is fixed on the bottom plane of the upper mounting plate; when an input laser beam projects on the tapered body of the conical mirror in a manner of being perpendicular to the bottom plane of the conical mirror, a laser reflecting plane perpendicular to the input laser can be formed
Data Source
AI summary
A laser projection module with a conical reflector supported by thin walls comprises: an upper mounting plate, a lower mounting plate with an aperture set in the center and a conical reflector which is provided on the upper mounting plate corresponding to the aperture, wherein at least three thin-walled supporting slices surrounding the conical mirror, are provided between the upper mounting plate and the lower mounting plate there are provided. The disclosure has a compact structure. With the support of the thin walls, the laser divided is self-assembled and the mechanical principle that side faces of the thin-walled slices have high resistance is satisfied, so that reliability and precision of the use of the conical mirror in a laser projection apparatus with the conical mirror are guaranteed. The support pattern of the conical mirror by thin walls is also applicable to various conical mirrors in other application occasions.