Integrally-Molded Laser Sensor Optical Window and Holder
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Solution Overview
Problem
Existing laser sensors face challenges in achieving high accuracy and durability for their optical windows, particularly in terms of shape accuracy, dustproof and waterproof properties, weight reduction, and miniaturization, due to manufacturing errors and material compatibility issues during the assembly of separate optical windows and holders.
Innovation Solution
The integration of optical windows and holders as a single, molded resin product with a light shielding component, which reduces the need for separate assembly, enhances rigidity, and minimizes shape distortion, while providing excellent dustproof and waterproof properties and enabling weight reduction and miniaturization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the optical window is manufactured separately and joined to the holder, then the manufacturing process is flexible, but the shape accuracy and surface quality of the optical window deteriorate due to bending errors and injection molding errors
Solution Approach 1:
The optical window and holder are merged into a single integrated component manufactured by injection molding. This eliminates the separate bending and joining processes, thereby eliminating the associated shape errors and surface quality deterioration while maintaining manufacturing efficiency through a single-step process.
2Ease of manufacture
If the optical window is joined to the holder using adhesive, then the assembly is simple, but the surface shape of the optical window is distorted by stress
Solution Approach 1:
The optical window and holder are integrated into a single molded part, completely eliminating the adhesive joining process. This removes the source of stress-induced surface distortion while maintaining the simplicity of assembly through a single integrated component.
3Strength
If the optical window is made of resin and the holder is made of metal, then the strength is high, but the joined part is easily peeled off due to difference in linear expansion
Solution Approach 1:
Both the optical window and holder are made of the same resin material with identical linear expansion characteristics. This eliminates the differential thermal expansion problem that causes joint peeling, while maintaining sufficient strength through the integrated molded structure.
4Strength
If separate components are joined to secure strength, then the structural integrity is maintained, but the weight and size increase
Solution Approach 1:
The optical window and holder are merged into a single integrated component, eliminating the weight of separate parts and joining materials. The structural integrity is maintained through the integrated molded design, achieving weight reduction and miniaturization suitable for compact moving bodies like drones.
5Measurement precision
If the optical window has a curved surface, then the optical performance is improved, but manufacturing errors such as shape error and thickness error increase
Solution Approach 1:
The curved optical window is integrated with the holder as a single molded part. This eliminates the separate bending process that introduces shape errors, allowing the curved surface to be formed directly during injection molding with consistent thickness and high accuracy, thereby maintaining optical detection 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
This approach results in a laser sensor with improved accuracy, reduced shape variation, enhanced durability, and easier maintenance, while allowing for compact designs suitable for applications like drones.
Implementation Method 1
an optical window that transmits the laser light and the reflection light
Implementation Method 2
a light shielding part that is located at least adjacent to the optical window and shields the laser light and ambient light
Data Source
AI summary
Provided is a laser sensor including an optical window with high accuracy and having excellent dustproof and waterproof properties. The laser sensor includes: a light projector; a light receiver to detect reflection light from a detection object to which laser light is emitted from the light projector; and an exterior component covering the light projector and the light receiver, in which the exterior component includes an optical window that transmits the laser light and the reflection light, and a holder that surrounds an outer periphery of the optical window, the optical window and the holder are formed as an integrally-molded product made of a resin having transmittivity in a wavelength band of the laser light, the optical window includes a pair of curved optical surfaces facing each other, and the holder includes: a gate part at a position relatively distant from the optical window; and a light shielding part that is at least adjacent to the optical window and shields the laser light L1 and ambient light.