Light Source Module Thermal Stability via Intermediary Adhesive
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Solution Overview
Problem
Existing light source modules for small projection-type display units, such as pico projectors, face challenges in adjusting the light-emission point position due to low thermal conductivity of UV adhesives and wet-type curing agents, leading to output decline during high temperature operation, and complex adjustment processes.
Innovation Solution
A light source module design featuring a radiator with multiple light-emitting elements, collimated lenses, first optical elements that adjust the optical axis direction, and a second optical element for multiplexing, which simplifies the adjustment process and maintains thermal stability by minimizing thermal expansion differences between components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If UV adhesive or wet-type curing agent is used to fix the LD, then the LD can be securely fixed after adjustment, but the low thermal conductivity of the adhesive causes output decline during high temperature operation
Solution Approach 1:
The patent introduces a specialized adhesive layer as an intermediary between the LD and heatsink. This adhesive is specifically selected to have high thermal conductivity (≥1 W/mK) to serve as a thermal transfer medium, replacing the conventional low thermal conductivity UV adhesives. The adhesive maintains the mechanical bonding function while simultaneously providing efficient heat dissipation path, thus resolving the contradiction between fixing stability and thermal performance.
2Manufacturing precision
If the light-emission point position is adjusted by installation location and lens, then the beam position can be precisely controlled, but the adjustment process becomes complex and time-consuming
Solution Approach 1:
The patent pre-configures the relative positions of the LD, collimating lens, and focusing lens during the manufacturing process. The optical components are arranged in predetermined positions that automatically achieve the desired light-emission point alignment. This preliminary positioning eliminates the need for complex post-assembly adjustments, significantly reducing adjustment time while maintaining manufacturing precision.
Solution Approach 2:
The patent combines multiple adjustment functions into a single integrated optical assembly. The collimating lens and focusing lens are positioned relative to each other and to the LD in a fixed configuration that simultaneously controls both the beam collimation and the light-emission point position. This merging of functions simplifies the overall adjustment process compared to separate adjustment of each component.
3Ease of manufacture
If thermal expansion differences between components are not minimized, then the structure can be simpler to manufacture, but the light-emission point position becomes unstable during temperature changes
Solution Approach 1:
The patent carefully selects materials for the LD, heatsink, and adhesive based on their thermal expansion coefficients. The adhesive is specifically chosen to have thermal expansion properties that match well with both the LD and heatsink materials. By controlling the thermal expansion parameter of the adhesive layer, the patent minimizes relative displacement between components during temperature changes, maintaining light-emission point stability without complicating the manufacturing process.
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 design allows for easier adjustment and stabilization of the light-emission point position, reducing output decline at high temperatures and simplifying the adjustment process, while maintaining high beam quality and durability.
Implementation Method 1
a radiator; a plurality of light-emitting elements disposed on the radiator
Implementation Method 2
a plurality of lenses each of which converts a light beam outputted from corresponding one of the plurality of light-emitting elements into a collimated light beam
Implementation Method 3
a plurality of first optical elements that each reflect the collimated light beam outputted from corresponding one of the plurality of lenses while adjusting an optical axis direction of the collimated light beam
Data Source
AI summary
A light source module according to an embodiment of the present disclosure includes: a radiator; a plurality of light-emitting elements disposed on the radiator; a plurality of lenses that each convert a light beam outputted from corresponding one of the plurality of light-emitting elements into a collimated light beam and output the collimated light beam; a plurality of first optical elements that each reflect the collimated light beam outputted from corresponding one of the plurality of lenses while adjusting an optical axis direction of the collimated light beam; and a second optical element that multiplexes respective light beams reflected from the plurality of first optical elements.