Light Emission Device Lid Lens Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing light emission devices face challenges in accurately controlling the shape and size of the light spot on a target surface due to misalignments and dimensional errors in the condenser lens and housing components, leading to fluctuations in the distance from the lens to the target.
Innovation Solution
A light emission device comprising a collimated light source, a planoconvex lens, and a housing with a lid that supports an optical member, where the lid is in contact with the planoconvex lens, allowing precise control of the distance and reducing variations in the light spot size and shape by minimizing manufacturing deviations in the lid's thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the condenser lens is secured in a lens holder by means of an adhesion layer and the lens holder is secured to a housing, then the device structure is flexible and easy to manufacture, but the distance from the lens to the target cannot be controlled with high accuracy due to misalignments and dimensional errors
Solution Approach 1:
The patent merges the lens holder and housing into a single integrated component. The lens is directly mounted within the housing structure itself, eliminating the separate lens holder and adhesion layer interface. This integration removes cumulative dimensional errors from multiple mounting interfaces, achieving high distance control accuracy while simplifying the overall device structure.
Solution Approach 2:
The patent introduces a precision-machined reference surface within the housing that serves as an intermediary for lens positioning. This reference surface provides a stable, accurately defined mounting plane that ensures consistent lens-to-target distance, acting as a mediator between the lens and housing to achieve high precision without complex assembly structures.
2Manufacturing precision
If multiple components (lens holder, housing, adhesion layer) are used to secure the condenser lens, then the device is easier to manufacture and assemble, but manufacturing deviations in each component accumulate leading to poor control of light spot shape and size
Solution Approach 1:
The patent combines the lens mounting structure and housing into a single integrated component manufactured as one piece. This eliminates the need for separate lens holders, adhesion layers, and multiple assembly steps, thereby removing cumulative manufacturing deviations while actually simplifying the manufacturing process through reduced part count and assembly operations.
3Manufacturing precision
If the distance from the condenser lens to the target is not precisely controlled, then the device structure can be simpler with more tolerance, but the shape and size of the light spot on the target cannot be controlled with high accuracy
Solution Approach 1:
The patent incorporates precision distance control features directly into the housing structure during the manufacturing process. By pre-defining the lens mounting position and distance relationships in the housing design itself, the system ensures accurate light spot quality from the outset without requiring complex adjustment mechanisms or post-assembly calibration procedures.
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 configuration enables high-accuracy control of the light spot shape and size on the target surface, enhancing irradiance distribution and optical coupling efficiency, particularly suitable for applications like automotive headlights and optical fiber processing.
Implementation Method 1
a planoconvex lens having a flat surface and a convex curved surface, the planoconvex lens being configured to converge collimated light that is emitted from the collimated light source to form a convergent beam
Data Source
AI summary
An optical member includes: a body portion having a first upper surface, and a second upper surface that is located above the first upper surface and surrounds the first upper surface in a plan view; a phosphor member disposed on the first upper surface; and a hold-down portion configured to secure the phosphor member such that the phosphor member is interposed between the hold-down portion and the body portion.