Optical Image Forming Device Resolving Parallelism Errors
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Solution Overview
Problem
Existing optical image forming devices face issues with distortion due to variations in adhesive thickness and parallelism between light reflecting surfaces, and manufacturing challenges such as tilted side surfaces in concave-convex plate members, leading to production quality deterioration.
Innovation Solution
The device alternately stacks glass and transparent resin plate members with refractive indices within a specific ratio, forming light reflecting portions between them, and uses a resin filling process to eliminate the need for adhesive agents, ensuring precise alignment and reducing distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive agents are used to join transparent plate members, then the light control panels can be assembled, but variations in adhesive thickness cause variations in distance or parallelism between adjacent light reflecting surfaces, leading to image distortion
Solution Approach 1:
The invention removes the adhesive agent from the assembly process entirely. Instead of using adhesive to join transparent plate members, the design allows direct contact between members, eliminating the source of thickness variation that causes parallelism errors and image distortion.
Solution Approach 2:
The transparent plate members are designed with pre-formed protruding portions and recesses that enable precise positioning and direct joining before final assembly. This preliminary structural design ensures accurate alignment without requiring adhesive layers, thereby maintaining parallelism between light reflecting surfaces.
2Productivity
If concave-convex plate members are manufactured by injection molding, then production efficiency is improved, but the vertical angle accuracy of opposing side surfaces deteriorates due to mold dimensional accuracy, causing tilted surfaces and quality deterioration
Solution Approach 1:
The invention divides the transparent plate member into multiple segments with protruding portions and recesses. This segmentation allows each part to be manufactured with standard precision while the assembled structure achieves the required vertical angle accuracy, avoiding the limitations of single-piece injection molding.
Solution Approach 2:
The invention changes the manufacturing approach from forming the entire component in one injection molding process to manufacturing segmented parts and assembling them. This parameter change in the manufacturing process enables better control over vertical angle accuracy through precise positioning features rather than relying solely on mold dimensional 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 allows for the production of optical image forming devices with high accuracy and minimal distortion, achieving precise parallelism and transparency while reducing manufacturing costs.
Implementation Method 1
a refractive index of the resin plate member falls within a range of 0.9 to 1.1 times (preferably 0.95 to 1.05 times, more preferably 0.98 to 1.02 times) a refractive index of the glass plate member
Data Source
Figure 1
Figure 2(A)~2(B)
Figure 3(A)~3(B)
AI summary
In an optical image forming device 10, glass plate members 14 and transparent resin plate members 15 each having a rectangular cross-section and the same dimensions are alternately stacked on each other, a light reflecting portion 13 is formed between the glass plate member 14 and the resin plate member 15, the refractive index of the resin plate member 15 falls within the range of 0.9 to 1.1 times the refractive index of the glass plate member 14, and a light input side light control panel and a light output side light control panel 11, 12, with the glass plate members 14 which are adjacent across the resin plate member 15 being joined to each other by only a resin of the resin plate member 15, are stacked on each other so as to make the light reflecting portions 13 orthogonal to each other in planar view. A manufacturing method includes forming a laminated body 22 by stacking a plurality of rectangular transparent plate members 20 alternately shifted from each other by a predetermined length in the widthwise direction so as to form protruding portions 21, forming light reflecting portions 13 on opposing surfaces 16 of the adjacent protruding portions 21, filling a gap region 26 between the adjacent protruding portions 21 with a transparent resin 27, manufacturing material members 29, 30 by cutting the protruding portions 21 integrated by a resin, and stacking paired light control panels 11, 12 manufactured by planarizing both end faces in the widthwise direction so as to make the light reflecting portions 13 orthogonal to each other in planar view.