Light Source Device Lens Fixation via Dual-Side UV Curing
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Solution Overview
Problem
Existing light source devices face challenges in achieving high accuracy and simplicity due to issues with curing photopolymerizable resin, leading to potential misalignment and reduced accuracy of the coupling lens, especially when the resin is not cured evenly, which can cause the lens to move during curing.
Innovation Solution
A light source device manufacturing method that includes a holder with a reflecting surface to direct curing light onto the photopolymerizable resin from both the front and rear sides of the coupling lens, ensuring even curing and secure fixation, using a semiconductor laser and a coupling lens with photopolymerizable resin applied between the lens and the holder, and a reflecting member to facilitate complete curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If photopolymerizable resin is provided only between the coupling lens and the holder, then the structure is simple, but the lens cannot be firmly fixed when the lens is relatively thin
Solution Approach 1:
The patent extends the photopolymerizable resin from a two-dimensional application (only between lens and holder) to a three-dimensional configuration that protrudes from the front and rear surfaces of the lens. This dimensional extension allows the resin to bond the lens at multiple locations simultaneously, providing firm fixation for thin lenses while maintaining structural simplicity.
2Device complexity
If ultraviolet ray is irradiated from the front of the coupling lens, then the structure is simple, but the photopolymerizable resin is not cured evenly due to refraction
Solution Approach 1:
The patent introduces a reflecting member positioned at the rear of the coupling lens to reflect ultraviolet light onto the photopolymerizable resin. This creates a dual-path curing system where light reaches the resin from both the front (through the lens) and the rear (via reflection), ensuring even curing across all portions of the resin without complicating the overall curing structure.
3Productivity
If the photopolymerizable resin is not cured completely, then the manufacturing process is faster, but the coupling lens moves during curing reducing accuracy
Solution Approach 1:
The patent uses a reflecting member to pre-direct ultraviolet light onto all portions of the photopolymerizable resin simultaneously before complete curing occurs. This preliminary action ensures that the resin is uniformly cured from both front and rear surfaces, preventing lens movement during the curing process and maintaining high positioning accuracy.
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 method ensures the coupling lens is firmly fixed and accurately positioned, enhancing the overall accuracy and simplicity of the light source device, allowing for efficient manufacturing and improved performance in image forming devices.
Implementation Method 1
irradiating an a curing light, such as an ultraviolet ray, for curing the photopolymerizable resin
Implementation Method 2
a reflecting member to facilitate complete curing
Implementation Method 3
a coupling lens that converts laser light from the semiconductor laser to a light flux
Data Source
AI summary
A method of manufacturing a light source device includes: preparing a holder for a semiconductor laser and a coupling lens having a first side confronting the semiconductor laser and a second side opposite to the first side, a photopolymerizable resin being provided on the holder at least at a location between the coupling lens and the holder; locating a light source for emitting a curing light for curing the photopolymerizable resin on an opposite side of the semiconductor laser with respect to the coupling lens, a reflecting member being provided on an opposite side of the light source with respect to the coupling lens; and curing the photopolymerizable resin by irradiating the curing light from the light source directly on a part of the photopolymerizable resin, and also on another remaining part of the photopolymerizable resin by reflecting the curing light on the reflecting member irradiating the curing light.