Laser Module Assembly With Adjustable Focus and Integrated Heat Sink
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing lamp manufacturing processes are complex and costly due to the need for multiple lenses to achieve light diffusion, which limits the ability to create lamps that can adjust focal length and produce aesthetically pleasing, star-like light patterns.
Innovation Solution
A laser module design where a heat sink and lens module are integrated within a height adjustment barrel, allowing for adjustable focal length between the laser diode and lens, comprising a lens holder, light diffusion plate, and heat sink with threaded connections for easy assembly and focal adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If one lens is provided for each LED to achieve light diffusion, then light diffusion effect is improved, but manufacturing process becomes complicated and costly
Solution Approach 1:
The patent merges multiple lens functions into a single integrated lens structure. Instead of providing separate lenses for each LED, the invention uses one lens that can serve multiple LEDs, thereby simplifying the manufacturing process while maintaining the light diffusion effect. This is achieved through a unified lens design that accommodates multiple light sources.
Solution Approach 2:
The lens structure is designed to perform multiple functions simultaneously. A single lens serves multiple LEDs, providing both light diffusion and focusing capabilities. The lens can adjust its focal length to achieve different optical effects, making it a universal component that replaces what would traditionally require multiple specialized lenses.
2Ease of manufacture
If focal length is fixed, then manufacturing is simplified, but ability to adjust illumination pattern is reduced
Solution Approach 1:
The patent introduces a dynamic adjustment mechanism that allows the focal length to be changed. The lens structure includes movable components that enable adjustment of the focal length according to different illumination requirements. This dynamic capability is achieved through a mechanical adjustment system that can be operated during installation or use.
Solution Approach 2:
The adjustment mechanism is nested within the lens structure itself. The movable lens elements or adjustment components are integrated into the overall lens assembly, allowing for compact design while maintaining adjustability. The nesting principle enables the adjustment mechanism to be housed within the lens body without significantly increasing the overall size.
3Illumination intensity
If multiple components are used for lens assembly, then optical performance is improved, but assembly complexity increases
Solution Approach 1:
The patent combines multiple optical components into a single integrated lens assembly. Instead of separately assembling multiple lenses and support structures, the invention uses a unified lens module that integrates the optical elements and their mounting structures. This reduces the number of assembly steps while maintaining optical performance.
Solution Approach 2:
The lens assembly is segmented into modular components that can be pre-assembled and tested separately, then quickly installed as a complete unit. This segmentation allows for simplified manufacturing of individual components while reducing on-site assembly complexity. The modular design enables easy replacement and maintenance.
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
Enables convenient focal length adjustment for optimized illumination, effective heat dissipation, and compact design suitable for various lamp applications, extending the service life and enhancing aesthetic appeal.
Implementation Method 1
a heat sink and a lens module are configured to be installed in an inner cavity of the height adjustment barrel respectively through two ends of the height adjustment barrel
Implementation Method 2
a laser diode received in an inner cavity of the heat sink and a lens accommodated within the lens module are aligned along a same optical axis
Data Source
AI summary
The present invention provides a laser module and an assembly method therefor. The laser module is mainly consisted of a lens module configured to be installed in an inner cavity of the height adjustment barrel through an end of the height adjustment barrel and a heat sink threadingly connected with another end of the height adjustment barrel. The laser module is configured in such a manner that a laser diode received in an inner cavity of the heat sink and a lens accommodated within the lens module are aligned along a same optical axis, and the height adjustment barrel is configured to adjust a focal length between the laser diode and the lens.