Optical Module Lens Adjustment via Constricted UV Resin Support
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Solution Overview
Problem
Existing optical modules face challenges in precisely adjusting the optical axis of lenses and filters due to limitations in adhesives like ultraviolet curable resin, which restricts the adjustment of the height and direction of these components, leading to potential shifts during use.
Innovation Solution
The optical module employs supporting members made of ultraviolet curable resin with a constriction, allowing for sufficient thickness to adjust the height and direction of lenses and filters, enhancing the freedom of adjustment and preventing optical axis shifts, while also being held securely by protrusions on the base member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ultraviolet curable resin is used as adhesive to mount lenses and filters, then the components can be fixed to the base member, but the resin thickness is insufficient to allow adequate adjustment of height and direction, leading to potential optical axis shifts
Solution Approach 1:
The supporting member is divided into multiple functional regions: a first region that contacts the base member, a second region that contacts the lens or filter, and an intermediate region connecting them. This segmentation allows each region to be optimized independently - the first region provides stable mounting on the base member while the second region enables precise adjustment of the optical component's position and orientation.
Solution Approach 2:
The supporting member extends in the thickness direction (z-axis) beyond what a simple adhesive layer would provide. By increasing the dimension in the thickness direction, the patent creates sufficient space for adjusting both the height (vertical position) and direction (angular orientation) of lenses and filters, thereby enabling precise optical axis alignment that cannot be achieved with conventional thin adhesive layers.
2Ease of operation
If the supporting member is made thicker to allow adjustment of lens height and direction, then adjustment freedom increases, but the structural stability and secure fixation may be compromised
Solution Approach 1:
Different regions of the supporting member have different structural characteristics optimized for their specific functions. The first region (contacting the base member) is designed for stable fixation with sufficient contact area, while the second region (contacting the lens) provides adjustment capability. The intermediate region transitions between these two, creating a structure that is both stable and adjustable without compromising overall reliability.
3Manufacturing precision
If conventional adhesive layers are used to mount optical components, then the structure remains simple, but the optical axis cannot be precisely adjusted and may shift during use
Solution Approach 1:
The supporting member is designed with built-in adjustment capabilities before the optical components are permanently fixed. The structure allows for preliminary adjustment of lens height and direction during assembly, enabling precise optical axis alignment to be established before final curing of the ultraviolet curable resin. This preliminary action ensures accurate positioning without requiring excessive thickness.
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 configuration enables precise adjustment and secure fixation of lenses and filters, ensuring stable optical performance and preventing optical axis shifts, even under varying temperatures, thus improving the overall optical module's accuracy and compactness.
Implementation Method 1
a first supporting member disposed between the base member and the lens, configured to support the lens with respect to the base member, and comprising an ultraviolet curable resin
Data Source
AI summary
An optical module includes a light forming part and a protective member that has an emitting window transmitting light from the light forming part and is disposed to surround the light forming part. The light forming part 20 includes a base member, a semiconductor light-emitting element mounted on the base member, a lens mounted on the base member, and the first supporting member that is disposed between the base member and the lens and supports the lens with respect to the base member. The first supporting member has constriction, which has a smaller cross-sectional area than a region in which the first supporting member is in contact with the lens and a region in which the first supporting member is in contact with the base member in a cross section perpendicular to a thickness direction of the first supporting member.