Lens Tool Mark Angle for Sharp Line Boundaries
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Solution Overview
Problem
Line generators using laser diodes and other light sources often produce lines with non-sharp boundaries and suffer from ghosting due to diffraction from tool marks, lacking a lens and mold design that achieves a rectangular light distribution pattern with sharp boundaries.
Innovation Solution
A lens and mold design where the optical surface's tool mark inclination is between 40 to 50 degrees in 80% of the surface area, preventing diffraction-induced ghosts and maintaining acceptable surface roughness, and a machining method that aligns the machining path at a similar angle to achieve these specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional lenses with optical surfaces satisfying specifications are used, then the lens can be manufactured with standard processes, but the boundaries in the line width direction are not sharp and ghosts appear
Solution Approach 1:
The patent changes the orientation parameter of tool marks on the optical surface, specifically controlling the inclination angle to be between 40-50 degrees relative to the X-axis. This parameter change in tool mark orientation prevents diffraction-induced ghosts while maintaining manufacturing feasibility through conventional machining processes
2Object-generated harmful factors
If the optical surface is machined to reduce tool mark inclination, then ghosting is reduced, but surface roughness may become unacceptable
Solution Approach 1:
The patent identifies and controls the inclination angle parameter of tool marks, setting it to 40-50 degrees. This specific parameter range optimizes the balance between reducing diffraction ghosts and maintaining acceptable surface roughness, achieving both goals simultaneously through precise parameter specification
Solution Approach 2:
The patent applies partial action by controlling tool mark inclination in 80% or more of the optical surface area rather than requiring perfect control over the entire surface. This partial control approach achieves sufficient ghost reduction while maintaining manufacturing practicality
3Manufacturing precision
If the lens optical surface collimates light in both X-axis and Y-axis directions, then light is properly directed, but the line width distribution pattern does not achieve sharp rectangular boundaries
Solution Approach 1:
The patent applies local quality by making the optical surface collimate light only in the Y-axis direction (width direction) while intentionally avoiding collimation in the X-axis direction (longitudinal direction). This asymmetric local optical property creates sharp rectangular boundaries in the line width distribution pattern
Solution Approach 2:
The patent changes the optical functionality parameter of the surface, specifying that it should collimate or collect light in Y-axis direction alone without collimating in X-axis direction. This parameter specification achieves the desired rectangular light distribution with sharp boundaries
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 solution effectively eliminates ghosting and maintains acceptable surface roughness, ensuring a rectangular light distribution pattern with sharp boundaries in line generators, enhancing the precision and quality of line generation.
Implementation Method 1
the lens has an optical surface which does not collimate the light in X-axis direction and which collimates or collects the light in Y-axis direction alone
Implementation Method 2
ghosts due to diffraction caused by the transferred tool mark
Data Source
AI summary
A lens used for a line generating optical system is provided, wherein X-axis is defined in longitudinal direction of the generated line, Y-axis is defined in width direction and Z-axis is defined in direction of the optical axis and wherein the lens has an optical surface which does not collimate the light in X-axis direction and which collimates or collects the light in Y-axis direction alone, inclination of direction of transferred tool mark with respect to X-axis being from 40 to 50 degrees in an area of 80% or more of the optical surface.