Lens Adjusting Mechanism for Optical Axis Alignment

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Solution Overview

Problem

Lens modules often suffer from misalignment of the image beam with the optical axis due to manufacturing and assembly tolerances, leading to image distortion and decreased resolution in devices like projectors.

Innovation Solution

A lens adjusting mechanism comprising a light-valve case, lens case, fasteners, and a leaf spring assembly or thin elastic element, which allows for adjustable alignment of the optical axis by adjusting the distance between opening edges, using fasteners or combiners to compensate for tolerances and ensure image beam alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If lens modules are assembled using conventional fixed mounting methods, then assembly is simple and fast, but manufacturing and assembly tolerances cause misalignment between image beam and optical axis, resulting in image distortion and resolution decrease

Engineering Contradiction:
Improvealignment precisionVSAvoidadjusting mechanism complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies the dynamics principle by replacing fixed mounting with adjustable mounting mechanisms. The lens holder includes adjustment holes and positioning structures that allow the lens module to be dynamically repositioned after assembly. This enables alignment correction without requiring extremely tight manufacturing tolerances, resolving the contradiction between alignment precision and device complexity.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent applies parameter changes by providing multiple adjustment holes at different positions and depths in the lens holder. By changing the positioning parameters (which hole to use, how deep to insert the positioning pin), the alignment can be optimized. This allows the system to compensate for tolerance variations through parameter adjustment rather than requiring complex mechanical structures.

Inventive Principle:
Principle #35Parameter changes

2Reliability

If adjustable alignment mechanisms are added to compensate for tolerances, then image beam alignment with optical axis is improved, but device complexity and assembly difficulty increase

Engineering Contradiction:
Improvealignment accuracyVSAvoidassembly ease
Core Design Contradiction:
ReliabilityVSEase of operation

Solution Approach 1:

The patent applies segmentation by dividing the alignment adjustment into independent, modular components. The lens holder is separated from the housing with distinct adjustment holes, and the positioning pin can be independently inserted and adjusted. This modular segmentation allows for simple tool-free adjustment while maintaining high alignment accuracy, resolving the contradiction between reliability and ease of operation.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent applies self-service through the tool-free adjustment mechanism. The positioning pin can be manually inserted into different adjustment holes without requiring special tools or complex procedures. Users can independently perform alignment adjustments themselves, improving ease of operation while maintaining reliable alignment through the multiple positioning options.

Inventive Principle:
Principle #25Self-service

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

The mechanism effectively compensates for manufacturing and assembly tolerances, ensuring the image beam is parallel to the optical axis, thereby improving image quality and resolution on the screen.

Implementation Method 1

the leaf spring assembly has at least one leaf contact disposed between the first opening edge and the second opening edge and abutting against the first opening edge or the second opening edge

Methodology Applied
Scientific EffectElasticity: Elasticity

Implementation Method 2

The thin elastic element has at least an elastic hook, attached to the through-hole edge

Methodology Applied
Scientific EffectElasticity: Elasticity

Data Source

PatentUS11378767B2Lens adjusting mechanism
Publication Date: 2022.07.05 YOUNG OPTICS
  • US11378767B2 patent drawing
  • US11378767B2 patent drawing
  • US11378767B2 patent drawing

AI summary

A lens adjusting mechanism includes a light-valve case, a lens case, one fastener, and a leaf spring assembly. The light-valve case has an emitting opening and a first opening edge, disposed on the peripheral portion of the emitting opening. The lens case has a light-path entrance and a light-path exit. The lens case also has a second opening edge. The second opening edge is disposed on the peripheral portion of the light-path entrance. The fastener is connected between the first opening edge and the second opening edge. The leaf spring assembly has at least one leaf contact. The leaf spring assembly is disposed between the first opening edge and the second opening edge. The leaf contact contacts the first opening edge or the second opening edge. The fastener is used to adjust the distance between the first opening edge and the second opening edge.