Integrated Light Source And Collimating Lens Assembly For Coaxial Alignment
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Solution Overview
Problem
Existing projection devices face challenges in achieving precise coaxial alignment and thermal management of collimating lenses due to limitations in injection molding precision, leading to poor coaxiality and thermal defocusing issues.
Innovation Solution
A machining process is used to create coaxially disposed mounting parts on a metal bracket for collimating lenses, combined with a heat-conductive member and heat-dissipating structure to improve alignment and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If injection molding process is used to manufacture slots for mounting collimating lenses, then manufacturing cost is reduced, but manufacturing precision and surface roughness deteriorate
Solution Approach 1:
The patent combines the collimating lens and light source into an integrated module where the collimating lens is directly mounted on the light source bracket. This merging eliminates the need for separate slots in the housing, thereby avoiding the precision limitations of injection molding while maintaining cost-effectiveness through integrated design and reduced assembly steps.
2Ease of manufacture
If plastic housing is used, then manufacturing cost is reduced, but heat conduction capability deteriorates
Solution Approach 1:
The patent introduces a heat-dissipating member as an intermediary component between the light source chip and the housing. This heat-dissipating member effectively conducts heat away from the light source, compensating for the poor thermal conductivity of the plastic housing, while the overall structure remains cost-effective.
3Adaptability or versatility
If multiple separate components are used for light source and collimating lenses, then assembly flexibility is improved, but device complexity increases
Solution Approach 1:
The patent merges the collimating lens and light source into a single integrated module with the collimating lens directly mounted on the light source bracket. This reduces the number of separate components and assembly steps, simplifying the overall device structure while maintaining optical performance.
4Ease of operation
If collimating lenses are mounted on housing with injection molded slots, then assembly ease is improved, but coaxiality control deteriorates
Solution Approach 1:
The patent integrates the collimating lens directly onto the light source bracket, eliminating the need for separate mounting slots in the housing. This integration ensures coaxial alignment between the light source and collimating lens while simplifying the assembly process, as the lens is positioned relative to the bracket rather than requiring precise fitting into housing slots.
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 coaxiality and reduces thermal defocusing, improving optical coupling efficiency and reducing manufacturing costs.
Implementation Method 1
a heat-conductive member disposed in a gap between the heat-dissipating member and the light source chip
Implementation Method 2
the heat-dissipating member being configured to dissipate heat of the bracket and the light source chip
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A light source and collimating lens integrated device, a lighting device and a projection apparatus. The light source and collimating lens integrated device comprises a shell (3); and a support (2) arranged in the shell (3), wherein the support (2) has a cavity; a first mounting part and a second mounting part are formed on an inner wall thereof, are coaxially arranged, and are machined to form a rotation body contour; a first collimating lens (4) is snap-fitted to the first mounting part; a second collimating lens (5) is snap-fitted to the second mounting part; and a light source chip (1) is arranged at one end of the support (2), and light emitted by the light source chip is output after passing through the first collimating lens (4) and the second collimating lens (5). A machining process is used to treat the support (2) to form a mounting station which corresponds to the collimating lenses (4, 5) and has the rotation body contour, so as to achieve hole-axis matching between the support (2) and the collimating lenses (4, 5), namely, the axis of a hole of a rotation body of the support (2) coincides with the axis of the collimating lenses (4, 5), thereby effectively eliminating the accumulative tolerance of assembly of the collimating lenses (4, 5), and improving the coaxiality between the collimating lenses (4, 5).