Integrally Molded Imaging Element Array for Optical Alignment
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Solution Overview
Problem
Existing image forming apparatuses face issues with misalignment of lenses and optical path elements, leading to deteriorated imaging and printing performance due to deviations in optical axes and surface accuracy requirements, which increase manufacturing time and complexity.
Innovation Solution
An imaging element array is designed with integrally molded imaging elements that include an incident surface, an emission surface, and reflective surfaces, where at least one reflective surface is formed on a convex portion protruding outward, with a reflective surface width less than the distance to the convex surface, allowing for improved alignment and surface accuracy, thereby suppressing deviations and simplifying the molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple lenses and apertures are combined to form a lens array, then imaging functionality is improved, but misalignment during assembly causes deterioration in imaging performance
Solution Approach 1:
The patent combines multiple lenses and apertures into a single integrated lens array structure. The lens array includes multiple lenses arranged in an array and multiple apertures arranged in an array, where each aperture corresponds to a respective lens. This integration eliminates misalignment issues between separate components while maintaining the desired imaging functionality.
2Manufacturing precision
If surface accuracy is increased to achieve desired imaging quality, then imaging performance is improved, but molding time increases
Solution Approach 1:
The patent applies surface accuracy requirements selectively - high accuracy is applied only to the reflective surfaces that directly affect imaging quality, while other surfaces have relaxed accuracy requirements. This partial application of high precision requirements reduces overall molding time while maintaining necessary imaging performance.
3Use of energy by moving object
If reflective surfaces are positioned where light flux width is wide, then optical efficiency is improved, but surface accuracy has greater effect on image formation requiring increased molding time
Solution Approach 1:
The patent positions reflective surfaces at locations where the light flux width is controlled to be moderate rather than maximum. This local optimization balances optical efficiency with reduced sensitivity to surface accuracy variations, thereby reducing molding complexity and time while maintaining adequate imaging performance.
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 effectively suppresses deviations between lenses and mirrors, enhances imaging performance by minimizing stray light, and simplifies the molding process, reducing manufacturing time and costs while maintaining high optical efficiency.
Implementation Method 1
Each imaging element includes a plurality of reflective surfaces. In the first reflective element, at least one of the plurality of reflective surfaces is formed on a top of a convex portion
Data Source
AI summary
An imaging element array includes a plurality of imaging elements that are arranged side by side. Each imaging element is integrally molded and includes an incident surface, an emission surface, and a plurality of reflective surfaces which is provided between the incident surface and the emission surface. The imaging element includes a first reflective element. In the first reflective element, at least one of the plurality of reflective surfaces is formed on a top of a convex portion which protrudes outwardly and has reflective sidewalls extending therefrom. In the first reflective element, a width of the reflective surface, which is formed on the top of the convex portion, in an arrangement direction thereof is less than a distance from an entrance into the concave portion to the top of the convex surface.