Light Source Module Optical Alignment and Thermal Safety
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Solution Overview
Problem
Existing spectrometer technologies have complex system configurations that are difficult to operate and maintain, particularly in remote sensing and process control applications, and require improved safety and usability features such as reduced size and thermal mass of light source modules to ensure safe operation in potentially explosive environments.
Innovation Solution
A light source module design featuring a thermally conducting base with a support feature, a mounting plate for a semiconductor laser, a rotationally symmetric lens cell, and a multi-conductor part with temperature sensors for optical ignition safety, using adhesives that cure by radiation and heat for precise alignment and assembly, and a thermoelectric cooler for temperature control, allowing for reduced size and mass while ensuring intrinsic safety and precise temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the light source module size and thermal mass are reduced, then safety in explosive environments and power consumption are improved, but manufacturing precision and assembly difficulty worsen
Solution Approach 1:
The patent replaces mechanical alignment systems with optical alignment methods. During assembly, the optical axis of the light source is aligned with the optical axis of the lens by observing the optical path directly, eliminating the need for complex mechanical positioning mechanisms. This reduces the mechanical structure size while maintaining alignment precision through optical feedback.
Solution Approach 2:
The patent changes the alignment parameter from mechanical dimensional measurements to optical path verification. By using the actual optical performance (light transmission and focus) as the alignment criterion rather than mechanical tolerances, the system achieves precise alignment in a compact configuration without requiring extensive mechanical adjustment mechanisms.
2Use of energy by moving object
If the light source module size is reduced, then power consumption and explosion risk are decreased, but assembly complexity increases
Solution Approach 1:
The patent merges the alignment and assembly operations into a single integrated process. The optical alignment is performed during the assembly process itself, and once aligned, the components are fixed in position. This combination eliminates the need for separate alignment and assembly steps, reducing overall assembly complexity despite the compact size constraints.
Solution Approach 2:
The patent performs preliminary optical alignment before final fixation of components. The light source and lens are positioned and aligned while accessible, then secured in place. This preliminary action ensures correct optical path establishment before the module is enclosed, simplifying the overall assembly process for the compact design.
3Temperature
If thermal mass is reduced, then temperature control response time is improved, but heat dissipation capability worsens
Solution Approach 1:
The patent applies local quality by providing enhanced heat dissipation specifically at the light source mounting location through a thermally conductive plate with direct thermal path to the heat sink, while maintaining low overall thermal mass in the rest of the module. This localized thermal management allows fast temperature response of the light source without compromising heat dissipation capability.
Solution Approach 2:
The patent introduces a thermally conductive intermediary plate between the light source and the heat sink. This intermediary provides an efficient thermal conduction path for heat dissipation while being thin enough to minimize overall thermal mass, enabling both rapid temperature control response and effective heat removal from the compact module.
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 enables a compact, easily assembled, and safely operable light source module with improved thermal control and intrinsic safety, reducing the need for explosion protection measures and allowing for precise wavelength control, thus enhancing the usability and reliability of spectrometer systems in hazardous environments.
Implementation Method 1
using adhesives that cure by radiation and heat for precise alignment and assembly
Implementation Method 2
using adhesives that cure by radiation and heat for precise alignment and assembly
Implementation Method 3
a thermoelectric cooler for temperature control, allowing for reduced size and mass while ensuring intrinsic safety and precise temperature control
Implementation Method 4
positioning and holding the lens cells within the sleeve at the focal distance from the base as to provide a desired focal length of the radiation from the light source to the lens
Data Source
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AI summary
A light source module may include a base with a support feature protruding from a surface of the base and securing a light source to direct radiation away from the surface. A lens cells may be attached proximate to the surface, optionally by being secured within a sleeve that is attached at one end to the surface. A multi-conductor part may include electrical conductors and a base temperature sensor that contacts the base. The base temperature sensor may be electrically connected to at least one of the plurality of conductive elements and further connected to an optical ignition safety protection system configured to interrupt current to the light source if the base temperature sensor indicates that a temperature of the light source is outside of a safe range.