Integral Light Module Mounting for Precise Micro-Mirror Alignment
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Solution Overview
Problem
Existing lighting devices for motor vehicles face challenges in achieving precise positioning of optical components due to assembly tolerances and the use of bulky printed circuit boards, especially when microelectromechanical systems with mirrors are involved.
Innovation Solution
A single-piece aluminum support structure is used to house the light source, optical shaping device, and optical projection device, with precise alignment of optical axes and components fixed to ensure accurate positioning, including a microelectromechanical system on a printed circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple parts are assembled together to form the support, then the device complexity is reduced and ease of manufacture is improved, but the manufacturing precision and positioning accuracy of optical components deteriorate due to assembly tolerances
Solution Approach 1:
The support is designed as a single-piece body integrating multiple functions: housing the light source, optical shaping device, optical projection device, and microelectromechanical system. This monolithic structure eliminates assembly tolerances between multiple parts while maintaining manufacturing feasibility through precision casting or molding techniques.
2Ease of manufacture
If a bulky printed circuit board is used to fix the microelectromechanical system, then the ease of manufacture and assembly are improved, but the device volume increases and positioning precision deteriorates
Solution Approach 1:
The printed circuit board carrying the microelectromechanical system is integrated directly into the single-piece support body, eliminating the need for a separate bulky board mounting structure. This reduces overall device volume while maintaining assembly simplicity through direct integration.
Solution Approach 2:
The support body is designed with a compact three-dimensional arrangement that positions the microelectromechanical system in a space-efficient manner, reducing the device footprint while maintaining all necessary functional clearances and optical paths.
3Manufacturing precision
If a single-piece support is used, then the manufacturing precision and positioning accuracy of optical components are improved, but the device complexity increases and ease of manufacture decreases
Solution Approach 1:
The single-piece support body serves multiple functions simultaneously: structural housing, optical component mounting, thermal management, and positioning reference. This multi-functionality reduces the need for separate components while maintaining manufacturing feasibility through standardized production processes.
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
Ensures exact positioning of optical components, enhancing image definition and sharpness by minimizing assembly tolerances and utilizing a compact design.
Implementation Method 1
a microelectromechanical system serving as a deflector for the laser light
Implementation Method 2
The deflector can be controlled so as to modulate the light image thus produced
Implementation Method 3
a phosphor-type luminophore element capable of converting the monochromatic light reflected by the deflector
Implementation Method 4
an optical device comprising several lenses receiving the white light coming from the luminophore element
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a support (4) for a light module (2), particularly for a motor vehicle, comprising a receiving area for at least one light source (16); a receiving area for an optical device for shaping the light emitted by the light source(s) (16); a receiving area for a microelectromechanical system with at least one mirror adapted to receive the rays from the optical shaping device; and a receiving area for at least one optical projection device (22) receiving the rays reflected by the mirror(s) of the microelectromechanical system (8). The support (4) forms a cavity (30) with an opening and comprises an outer surface around said opening, said surface forming the receiving area of the microelectromechanical system.