Optical Holder Welding Structure for Stable Axis Alignment
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Solution Overview
Problem
Existing optical units face challenges in maintaining desired optical characteristics due to relative positional shifts between holders during the welding process, which can lead to suboptimal alignment and performance of optical devices.
Innovation Solution
The optical unit design features sleeve-shaped holders with matching fitting portions that are welded together, ensuring equal welding widths on both sides of the optical axis, thereby minimizing contraction and maintaining the relative positional stability of optical devices during the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laser welding is performed to fix the lens holder and laser holder together, then the holders are securely fixed, but relative positional shifts occur between holders during welding, degrading alignment precision
Solution Approach 1:
The patent applies preliminary action by performing relative positional adjustment between the lens holder and laser holder before welding. The holders are positioned and adjusted to achieve desired optical characteristics, then fixed in this adjusted state through laser welding. This ensures that the precise alignment is established before the welding process begins, preventing degradation of alignment precision during fixing.
Solution Approach 2:
The patent applies local quality by making the fitting portions of the holders from the same material with identical thermal expansion coefficients. This localized material uniformity ensures that both holders expand and contract uniformly during welding, preventing relative positional shifts and maintaining alignment precision between different holder components.
2Strength
If holders are welded together, then strong fixation is achieved, but non-uniform contraction occurs during welding, causing positional instability
Solution Approach 1:
The patent applies local quality by making the fitting portions of the holders from the same material with identical thermal expansion coefficients. This localized material uniformity ensures that both holders expand and contract uniformly during welding, preventing relative positional shifts and maintaining alignment precision between different holder components.
Solution Approach 2:
The patent applies homogeneity by ensuring that the fitting portions of both holders have uniform material composition and thermal properties. This homogeneity in material characteristics causes the holders to respond uniformly to thermal changes during welding, eliminating differential contraction that would otherwise cause positional instability.
3Manufacturing precision
If relative positional adjustment is performed before welding, then desired optical characteristics are achieved, but the adjustment time increases manufacturing complexity
Solution Approach 1:
The patent applies preliminary action by performing relative positional adjustment between the lens holder and laser holder before welding. The holders are positioned and adjusted to achieve desired optical characteristics, then fixed in this adjusted state through laser welding. This ensures that the precise alignment is established before the welding process begins, preventing degradation of alignment precision during fixing.
Solution Approach 2:
The patent applies local quality by making the fitting portions of the holders from the same material with identical thermal expansion coefficients. This localized material uniformity ensures that both holders expand and contract uniformly during welding, preventing relative positional shifts and maintaining alignment precision between different holder components.
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 approach allows for the formation of an optical unit with desired optical characteristics by ensuring that the holders contract uniformly, thereby maintaining the precise alignment and performance of the optical devices even after welding.
Implementation Method 1
a welded portion that is melted and solidified over the first fitting portion and the second fitting portion in the overlapping portion
Implementation Method 2
the welded portion being formed such that a first welding width at a center of the first fitting portion in a thickness direction of the first fitting portion and a second welding width at a center of the second fitting portion in a thickness direction of the second fitting portion are substantially identical in the optical axis direction of the optical unit
Data Source
AI summary
An optical unit includes: a first optical device holding body that is sleeve-shaped and includes a first holding portion configured to hold therein at least one first optical device, and a first fitting portion extending from the first holding portion; a second optical device holding body that is sleeve-shaped and includes a second holding portion configured to hold therein at least one second optical device, and a second fitting portion extending from the second holding portion; and a welded portion that is melted and solidified over the first fitting portion and the second fitting portion in an overlapping portion between the first fitting portion and the second fitting portion. A first welding width at a center of the first fitting portion and a second welding width at a center of the second fitting portion are substantially identical in the optical axis direction of the optical unit.