Optical Holder Assembly for Lens Array Alignment Stability
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Solution Overview
Problem
Lens mirror arrays in optical devices, such as those used in printers and copying machines, are prone to bending and warping due to their long, flexible structure, making it difficult to accurately position the incident-side lens surfaces with respect to the light emitting unit, which affects the precision of image formation.
Innovation Solution
A holder is designed with multiple positioning surfaces that allow the lens mirror array and light source unit to be fixed in a stable, accurately aligned state, eliminating the need for complex adjustments by using surface contacts and adhesives or leaf springs to maintain alignment during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the lens mirror array is made with a long structure to match the photoconductive drum length, then the coverage area is improved, but the structural stability deteriorates causing bending and warping
Solution Approach 1:
The lens mirror array is divided into multiple individual optical elements that are separately positioned and fixed to the holder, rather than being a single long continuous structure. This segmentation allows each element to be independently stabilized while collectively providing the required coverage area.
Solution Approach 2:
A holder structure is introduced as an intermediary component between the lens mirror array and the light emitting unit. The holder provides rigid support and positioning surfaces that prevent bending and warping of the optical elements, thereby maintaining structural stability while enabling the required coverage area.
2Ease of manufacture
If the lens mirror array is made flexible to ease manufacturing, then the ease of manufacture is improved, but the positioning precision deteriorates making accurate alignment difficult
Solution Approach 1:
Positioning surfaces are provided on the holder before the optical elements are fixed. These pre-prepared positioning surfaces guide the optical elements into their correct positions during assembly, ensuring high positioning precision while maintaining manufacturing ease through simplified assembly procedures.
Solution Approach 2:
Complex mechanical adjustment mechanisms for positioning are replaced by precision-machined positioning surfaces on the holder. The positioning is achieved through precise surface contact geometry rather than mechanical adjustment, thereby maintaining ease of manufacture while achieving high positioning precision.
3Stability of the object's composition
If the lens mirror array is fixed rigidly to ensure stability, then the structural stability is improved, but the ease of operation deteriorates requiring complex adjustment procedures
Solution Approach 1:
The holder structure incorporates self-aligning positioning surfaces that automatically guide the optical elements into their correct positions during assembly. This self-service positioning mechanism eliminates the need for complex manual adjustment procedures while maintaining structural stability through rigid fixation.
Solution Approach 2:
Positioning surfaces are pre-configured on the holder to establish correct positions automatically during assembly. This preliminary preparation of positioning features simplifies the assembly operation while ensuring the optical elements are correctly positioned and firmly fixed for structural stability.
Data Source
AI summary
An optical device includes a light source unit, an optical member, and a holder formed by a single member. The light source unit includes a light source that emits light in a first direction and has a first positioning surface orthogonal to the first direction. The optical member is disposed to be separated from and opposed to the light source unit in the first direction and has an incident surface, an emission surface, and a second positioning surface. The holder has a third positioning surface and a fourth positioning surface, holds the light source unit in a state in which the first positioning surface of the light source unit is set in surface contact with the third positioning surface, and holds the optical member in a state in which the second positioning surface of the optical member is set in surface contact with the fourth positioning surface.