Diffusion Apparatus Lens Positioning and Sealing
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Solution Overview
Problem
Existing light source apparatuses face issues with optical performance due to variable distances between pickup lenses and the phosphor layer, caused by dimension errors in the main body and substrate, leading to inefficient light collection and modulation.
Innovation Solution
A diffusion apparatus with a substrate featuring recesses to precisely position a lens and diffuser, ensuring appropriate distance and sealing, and a pressing member to secure the lens without adhesives, preventing dust adhesion and gas production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If pickup lenses and phosphor layer are fixed to the main body, then the structure is simple, but the distance between lenses and phosphor layer varies due to dimension errors, degrading optical performance
Solution Approach 1:
The patent divides the light source apparatus into separate functional modules: the pickup lenses are mounted on a lens holder that is detachably coupled to the main body, while the phosphor layer remains fixed on the main body. This segmentation allows the lens assembly to be independently positioned and adjusted, eliminating the problem of cumulative dimension errors when all components are rigidly fixed to the main body.
Solution Approach 2:
The patent introduces a lens holder as an intermediary component between the pickup lenses and the main body. The lens holder provides precise positioning features (such as positioning holes and positioning protrusions) that ensure accurate alignment and maintain the required distance between the lenses and phosphor layer, while still allowing for assembly and disassembly.
2Ease of manufacture
If dimension errors occur in main body and substrate, then manufacturing is easier, but the distance between lenses and phosphor layer becomes inappropriate, reducing optical performance
Solution Approach 1:
The lens holder is pre-manufactured with precise positioning features (positioning holes, positioning protrusions, and recesses) that establish the correct distance and alignment between the pickup lenses and phosphor layer before final assembly. This preliminary preparation of positioning structures ensures that even if the main body or substrate have dimension errors, the optical components will be correctly positioned during assembly.
3Device complexity
If lenses are fixed using adhesives, then positioning is simple, but dust adhesion and gas production occur, degrading optical performance
Solution Approach 1:
The patent replaces the chemical bonding method (adhesives) with a mechanical positioning and pressing system. The lens holder includes pressing members that apply mechanical force to secure the pickup lenses in position through friction and normal force, eliminating the need for adhesives and thereby preventing dust adhesion and gas production that would occur with adhesive curing.
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
Enhances optical performance by maintaining precise lens positioning, reducing dust adhesion, and avoiding gas-related performance decreases, while minimizing the projector's size and complexity.
Implementation Method 1
a diffuser (65) that diffuses light
Data Source
AI summary
A diffusion apparatus includes a diffuser, a substrate to which the diffuser is fixed, and a first lens that has a curved surface and a flat surface located on the side opposite the curved surface and is so fixed to the substrate as to face the diffuser. The substrate includes a first recess having a first bottom surface and a first side surface that rises from the first bottom surface and a second recess having a second bottom surface connected to the first side surface and a second side surface that rises from the second bottom surface. The first lens is so disposed in the second recess that the flat surface is in contact with the second bottom surface. The diffuser is fixed to the first bottom surface.