Optical Member with Embedded Wire for Damage Detection
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Solution Overview
Problem
Existing 3D sensing systems lack a means to detect damage such as cracking or peeling in optical members, which can lead to harmful laser light emission and erroneous actuation in harsh environments, and are prone to cracking during reflow processes due to high heat resistance requirements.
Innovation Solution
An optical member with a wire containing an electrically conductive substance, such as silver, is applied using a printing process, allowing for detection of damage by monitoring the conducting state of the wire, and is manufactured using a hybrid material of plastic and inorganic glass for enhanced heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an optical member including a diffuser or diffractive optical element is used to diffuse laser light and reduce harm, then safety is improved, but the optical member may crack or peel due to impact or drops, causing undetected harmful laser emission
Solution Approach 1:
A wire containing an electrically conductive substance is embedded in the optical member before it is damaged, establishing a monitoring system in advance. This preliminary action enables continuous monitoring of the optical member's integrity, allowing detection of cracks or peeling before they cause harmful laser emission, thus resolving the contradiction between safety improvement and reliability maintenance
Solution Approach 2:
The monitoring unit continuously monitors the conducting state of the embedded wire and provides feedback about the optical member's condition. When damage occurs (cracking or peeling), the change in electrical conductivity provides immediate feedback, enabling timely detection and response to maintain reliability while the safety benefits of light diffusion remain active
2Adaptability or versatility
If the optical member is used in harsh environments (sunlight, vibration) for outdoor 3D sensing, then adaptability is improved, but damage detection capability deteriorates as no means exists to detect cracking or peeling
Solution Approach 1:
The wire containing an electrically conductive substance serves as an intermediary element embedded within the optical member. This intermediary provides a measurable physical quantity (electrical conductivity) that correlates with the structural integrity of the optical member, enabling indirect detection of damage in harsh outdoor environments where direct monitoring would be difficult
Solution Approach 2:
The invention replaces complex mechanical damage detection systems with an electrical monitoring system. By monitoring the electrical conducting state of the embedded wire, the system substitutes mechanical inspection methods with simpler electrical measurements, making damage detection feasible in outdoor 3D sensing applications
3Manufacturing precision
If high melting point lead-free solder is used in reflow process for bonding electrode to wiring board, then manufacturing precision is improved, but heating treatment temperature increases causing cracking in optical members
Solution Approach 1:
The optical member is constructed from composite materials with enhanced heat resistance, combining materials that can withstand the high temperatures of lead-free reflow soldering (240-260°C). This composite structure maintains manufacturing precision for electrode bonding while resisting thermal damage during the elevated temperature processing
4Productivity
If the optical member continues to be used without damage detection in known 3D sensing systems, then productivity is maintained, but safety deteriorates due to undetected harmful laser emission from damaged components
Solution Approach 1:
The optical member performs self-monitoring through the embedded wire and monitoring unit that continuously assess its own integrity. This self-service capability allows the system to maintain productivity through continuous operation while simultaneously detecting damage that could cause harmful laser emission, eliminating the need for external inspection systems
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
Enables early detection of damage in optical members, preventing injuries and accidents by preventing laser light emission and reducing the risk of blindness, while maintaining optical performance and durability during reflow processes.
Implementation Method 1
a wire containing an electrically conductive substance... monitoring a conducting state of the wire
Data Source
AI summary
The present disclosure provides an optical member for use in a laser module that includes a surface emitting laser, the optical member being capable of detecting damage (cracking, peeling, and the like), a method for manufacturing the optical member, a laser module including the optical member, and a laser device.