Optical Unit Holder Structure for Easier Prism Adhesive Bonding
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Solution Overview
Problem
Conventional prism modules face difficulties in injecting adhesive due to the elongated shape of groove parts, leading to challenges in bonding the optical element with the holder, especially when using needles with larger diameters.
Innovation Solution
The optical unit design includes a holder with side surface portions featuring concave portions that accommodate adhesive members, allowing for easier injection and bonding of the optical element, utilizing both thermosetting and ultraviolet curable adhesives to secure the optical element to the holder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If groove parts are formed as elongated shapes extending in the up-down direction, then the adhesive can be contained within the groove, but the opening at the upper end becomes small making it difficult to inject adhesive with larger diameter needles
Solution Approach 1:
The invention transforms the traditional elongated groove shape into a concave portion with a specific three-dimensional configuration. The concave portion has a bottom surface and side surfaces that form a pocket-like structure, changing from a simple linear groove to a volumetric feature that provides both adequate opening area for needle injection and sufficient containment for adhesive bonding.
Solution Approach 2:
The concave portion is designed with differentiated local characteristics: the opening area is sufficiently large to accommodate larger diameter needles, while the depth and bottom surface area are optimized for adhesive containment. This local optimization of different regions of the concave portion simultaneously addresses both the injection ease and bonding reliability requirements.
2Ease of operation
If the opening of the groove part is made larger to facilitate adhesive injection, then easier injection is achieved, but the containment and positioning precision of the adhesive may be reduced
Solution Approach 1:
By creating a concave portion with controlled depth and side surfaces, the invention adds a vertical dimension to adhesive containment. This three-dimensional structure allows the opening to be larger for easier injection while the depth and sidewalls provide precise positioning and containment, preventing adhesive overflow and ensuring accurate placement.
Solution Approach 2:
The concave portion is pre-formed in the holder before adhesive injection, creating a predetermined receptacle that guides and confines the adhesive. This preliminary structural preparation ensures that when adhesive is injected through the larger opening, it is automatically contained and positioned within the concave portion, maintaining manufacturing precision without requiring smaller openings.
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 design facilitates efficient adhesive application, improving bonding strength and stability, enabling quicker curing and reducing the risk of adhesive misalignment, thus enhancing the optical unit's performance and durability.
Implementation Method 1
a process of injecting an ultraviolet curable adhesive into the concave portion, a process of irradiating the ultraviolet curable adhesive with ultraviolet rays to cure the ultraviolet curable adhesive
Implementation Method 2
a process of heating the thermosetting adhesive to cure the thermosetting adhesive
Data Source
AI summary
An optical unit has an optical element reflecting light between intersecting first and second directions, and a holder. The holder includes a holder body extending in a third direction intersecting the first and second directions, and a pair of surface portions extending from the holder body in an intersection direction intersecting the third direction. The optical element is arranged between the surface portions. At least one surface portion has an inner surface facing the optical element, an end surface connected to an edge of the inner surface in an intersection direction, and a concave portion arranged astride the inner and end surfaces and recessed in the intersection direction from the end surface. The concave portion accommodates an adhesive member bonding the optical element with the holder. The length of the concave portion along the end surface is greater than the depth of the concave portion in the intersection direction.