Exposure Device Frame Member Positioning for LED Head Precision
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Solution Overview
Problem
Conventional exposure devices with concave-convex positioning structures face challenges in maintaining precise positional relationships between light-emitting elements and photoconductive bodies, leading to low positioning precision, image quality issues due to dust accumulation, and limitations in optical axis adjustment precision.
Innovation Solution
An exposure device with an elongated casing and frame member, where the frame member is fixed to the casing with a reference portion for precise positioning, and a method involving adhesive curing to secure the components, preventing warpage and maintaining image quality during cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If aluminum die casting is used to produce the LED head casing with high precision and rigidity, then positioning precision between light-emitting sections and photoconductive body is improved, but production cost increases and device size becomes larger
Solution Approach 1:
The LED head is divided into multiple components: the casing (110) made of resin, the light-emitting element (130), and the lens array (140). This segmentation allows each component to be manufactured separately using appropriate methods and then assembled, reducing overall production cost while maintaining positioning precision through dedicated positioning structures.
Solution Approach 2:
A positioning portion (114) with convex-protruding shape is introduced as an intermediary structure between the casing and light-emitting element. This positioning portion mediates the connection, ensuring precise positioning without requiring the entire casing to be manufactured with high precision through expensive die casting.
2Strength
If aluminum die casting is used to produce the LED head casing, then structural rigidity is improved, but device size becomes larger
Solution Approach 1:
The casing is made of resin instead of thick metal, allowing for a thinner-walled design that reduces overall device size. The resin casing (110) provides sufficient structural rigidity through optimized geometry and the addition of reinforcement ribs, eliminating the need for bulky metal construction.
Solution Approach 2:
The LED head combines resin material for the casing with metal or ceramic components for the light-emitting element and lens array. This composite approach allows each material to be used where it provides the most benefit, achieving required rigidity with minimal overall size.
3Manufacturing precision
If concave-convex positioning structure is used in the casing, then positioning function is provided, but fixing the light-emitting element to the casing becomes difficult while maintaining high precision positional relationship
Solution Approach 1:
The positioning portion (114) on the casing automatically guides and positions the light-emitting element during assembly. The convex shape of the positioning portion fits into a corresponding recess on the light-emitting element, creating a self-aligning connection that maintains high positional precision without requiring complex assembly procedures.
Solution Approach 2:
The positioning function and the fixing function are merged into a single integrated structure. The positioning portion (114) not only provides positioning but also serves as the primary fixing mechanism when combined with adhesive, eliminating the need for separate positioning and fixing components.
4Device complexity
If the lens array corner portions are pointed at right angles, then the lens array structure is simple, but cleaning becomes complicated as the cloth is caught by the corner portions
Solution Approach 1:
Instead of modifying the lens array corners to be rounded (which would complicate the lens array structure), the cover (400) is designed with its bottom surface extending below the lens array and featuring rounded corners. This inverts the solution approach by placing the rounded feature on the protective cover rather than the lens array itself, maintaining lens array simplicity while enabling easy cleaning.
Solution Approach 2:
The cover (400) acts as an intermediary element between the user's cleaning cloth and the lens array (140). The rounded bottom corners of the cover prevent the cloth from being caught, allowing smooth cleaning motion while the cover itself protects the lens array during the cleaning process.
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 ensures accurate exposure, easy cleaning of the lens array, and improved image quality by maintaining precise positional relationships and preventing deformation of the LED head, thus reducing production costs and enhancing the assembly process.
Implementation Method 1
adhesive curing to secure the components
Data Source
AI summary
There is provided an exposure device including an exposure head having a light-emitting member which has a plurality of light-emitting sections arranged in a row and a casing which holds the light-emitting member and which is elongated in a longitudinal direction orthogonal to an optical axis direction of a light emitted from the light-emitting sections; and an elongated frame member fixed to the casing and having a reference portion at which the frame member is positioned with respect to the light-emitting sections; wherein the frame member is fixed to the casing such that the frame member is positioned with respect to the light-emitting sections in both of the longitudinal direction and a width direction of the casing, the width direction being orthogonal to the longitudinal direction and the optical axis direction. The exposure device is capable of performing exposure precisely at a desired exposure position.