Integrated Laser Module Assembly for Stable 360° Line Projection
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Solution Overview
Problem
Existing laser leveling devices require complex and costly alignment processes for coaxial alignment of laser diodes and conical reflectors, which can lead to defocusing due to adhesive shrinkage, resulting in inaccurate and unstable laser markings.
Innovation Solution
The method involves integrating a beam splitter with the laser diode using plastic injection molding technology to form a negative cone for total reflection, eliminating the need for separate components and complex alignment, thereby creating a robust and stable laser module that can project a laser line over 360°.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conical reflector is fixed and aligned above the laser diode using a transparent spacer and adhesive, then coaxial alignment of the laser beam and conical reflector is achieved, but adhesive shrinkage during curing causes defocusing and reduces alignment stability
Solution Approach 1:
The patent merges the conical reflector and laser diode into a single integrated component where the conical reflector is directly formed as part of the laser diode housing or mounting structure. This eliminates the need for separate spacers and adhesive bonding, thereby removing the source of shrinkage-induced defocusing while maintaining precise coaxial alignment through direct integration.
2Manufacturing precision
If separate components (laser diode and conical reflector) are used with complex alignment procedures, then coaxial alignment can be achieved, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent combines the laser diode and conical reflector into a single integrated component, eliminating the need for separate alignment procedures. The conical reflector is directly formed as part of the laser diode housing or mounting structure, simplifying the manufacturing process while maintaining precise coaxial alignment.
Solution Approach 2:
The conical reflector is pre-formed as an integral part of the laser diode housing or mounting structure during the manufacturing process. This preliminary formation ensures that the reflector and laser diode are already in the correct relative positions before assembly, eliminating the need for complex post-assembly alignment procedures.
3Ease of manufacture
If separate components with spacers and adhesive are used, then the laser module can be assembled, but the final product has larger dimensions and reduced compactness
Solution Approach 1:
The patent merges the conical reflector and laser diode into a single integrated component, eliminating the need for separate spacers and adhesive layers. This direct integration significantly reduces the overall volume of the laser module while maintaining assembly feasibility through the unified structure.
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
This approach simplifies the manufacturing process, reduces errors and manufacturing tolerances, and results in a cost-effective, compact, and precise laser module with improved stability and accuracy, eliminating the need for complex alignment and assembly steps.
Implementation Method 1
a beam splitter of the laser module is manufactured in one piece with the laser diode by means of plastic injection molding in the form of a negative cone designed for total reflection
Data Source
Figure 1
Figure 2
Figure 3~3(d)
AI summary
The invention relates to a method for producing a laser module (32, 32a, 32c, 32d) of a laser levelling device (10), the laser module (32, 32a, 32c, 32d) being provided to generate a projectable laser line, in particular a laser line projectable over an angle range of 360°, and having at least one laser diode (18) for emitting laser light (20) in the emission direction. According to the invention, the method comprises a method step (116) in which a beam splitter (38, 38a, 38c, 38d) of the laser module (32, 32a, 32c, 32d) is produced by means of plastic injection-moulding in one piece with the laser diode (18), in particular in an interlocking, frictional and/or integrally bonded manner, in the form of an inverted cone (40, 40a, 40c, 40d) designed for total internal reflection.