Optical Member Mounting Precision Using Wavelength Conversion
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Solution Overview
Problem
Existing light emitting devices face challenges in achieving precise alignment between light sources and optical members, leading to suboptimal light characteristics and uniformity, particularly due to tolerances in mounting positions.
Innovation Solution
A method and apparatus that utilize a wavelength conversion unit to determine the positional information of a light source, allowing for precise alignment of an optical member by irradiating the unit with excitation light and using a sensing unit to capture and process the emitted light, thereby aligning the optical axis of the optical member with the light source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mounting methods are used to mount optical member on light source, then manufacturing process is simple, but mounting position precision is poor leading to suboptimal light characteristics
Solution Approach 1:
The patent applies preliminary action by pre-defining a reference position on the light source (using fiducial marks or wavelength conversion unit characteristics) before mounting the optical member. This allows the mounting position to be predetermined and measured in advance, ensuring high precision alignment while streamlining the actual mounting process through clear reference points.
Solution Approach 2:
The patent replaces purely mechanical mounting alignment methods with optical-based positioning systems. By using wavelength conversion units that emit light at specific wavelengths and fiducial marks detectable by sensors, the system substitutes mechanical alignment with optical field-based positioning, achieving sub-millimeter precision without complex mechanical adjustment mechanisms.
2Ease of manufacture
If mounting position tolerance is increased to simplify manufacturing, then manufacturing is easier, but light distribution uniformity deteriorates
Solution Approach 1:
The patent implements feedback by using sensors to detect the actual position of the light source's wavelength conversion unit or fiducial marks, comparing it with the predetermined reference position, and adjusting the optical member's mounting position accordingly. This closed-loop feedback system ensures that even with manufacturing tolerances, the final mounting position achieves the required precision for uniform light distribution.
3Manufacturing precision
If precise alignment of optical axis with light source is achieved, then light characteristics are improved, but measurement and detection difficulty increases
Solution Approach 1:
The patent introduces intermediary elements (fiducial marks and wavelength conversion units) that serve as measurable proxies for the actual light source position. These intermediaries emit light or reflect markers at known positions, allowing the optical axis alignment to be measured indirectly through their detectable signals rather than requiring direct measurement of the light source's optical center, which would be extremely difficult.
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 enhances precision and improves light characteristics by accurately matching the optical axis of the optical member with the light source, resulting in improved light distribution and reduced tolerance-related issues, leading to more uniform and effective light emission.
Implementation Method 1
a wavelength conversion unit to convert a wavelength of light; light is irradiated to the wavelength conversion unit to excite the wavelength conversion unit and obtaining positional information regarding the light source from light emitted from the wavelength conversion unit
Data Source
AI summary
There is provided a method of manufacturing a light emitting device including preparing a light source including a wavelength conversion unit and an optical member applied to the light source. Light is irradiated to the wavelength conversion unit to excite the wavelength conversion unit and positional information regarding the light source is obtained from light emitted from the wavelength conversion unit. A mounting position of the optical member is determined based on the obtained positional information regarding the light source. The method of manufacturing a light emitting device having excellent light characteristics can be obtained.