Phosphor Wheel Flexure Plate Alignment for Focus Tolerance Stack-Up
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Solution Overview
Problem
Stack-up of mechanical and optical tolerances in phosphor illumination systems degrades focus quality, and existing adjustment mechanisms like sliding lens barrels and cams increase cost and complexity without adequately addressing misalignments.
Innovation Solution
A flexure plate mechanism with adjustable and fixed fasteners allows for adjusting the distance and angle of the phosphor wheel relative to the condenser lens, using a resilient member to induce deflection and correct misalignments without additional lens adjustment mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical and optical tolerances are tightened to improve focus quality, then focus quality is improved, but manufacturing cost significantly increases
Solution Approach 1:
The patent applies parameter changes by modifying the physical state and properties of the flexure plate material. The flexure plate is made from a resilient material that can elastically deform under controlled stress, allowing the system to accommodate tolerance variations through material property selection rather than tight manufacturing tolerances. This resolves the contradiction by achieving good focus quality through material parameter optimization instead of costly precision manufacturing.
2Ease of operation
If sliding lens barrels and cams mechanisms are used to adjust lens position, then lens position adjustment is enabled, but device complexity and cost increase
Solution Approach 1:
The patent extracts the adjustment function from complex mechanical mechanisms (lens barrels and cams) and implements it through a simplified flexure plate system. The resilient flexure plate inherently provides the necessary compliance and adjustment capability through its elastic deformation, eliminating the need for separate adjustment mechanisms. This resolves the contradiction by maintaining ease of operation while dramatically reducing device complexity.
Solution Approach 2:
The flexure plate system is self-adjusting through elastic deformation in response to mounting tolerances and thermal variations. The resilient material automatically compensates for misalignments without requiring external adjustment mechanisms or complex control systems. This self-service capability resolves the contradiction by providing automatic adaptation while minimizing mechanical complexity.
3Ease of operation
If sliding lens barrels and cams mechanisms are used for lens adjustment, then lens position can be adjusted, but lens centration tolerance maintenance becomes difficult
Solution Approach 1:
The patent changes the mechanical stiffness parameter of the mounting structure by using a resilient flexure plate. This compliant structure allows the lens to self-center through elastic deformation, automatically maintaining centration tolerance during position adjustment. The flexible material absorbs misalignment stresses and guides the lens into proper alignment, resolving the contradiction between adjustability and centration precision.
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
The flexure plate mechanism effectively corrects focus misalignments due to tolerance stack-up, maintaining lens centration and ease of adjustment, reducing system complexity and cost.
Implementation Method 1
a flexure plate onto which the phosphor wheel is mounted. The flexure plate includes a fixed fastener for fixedly fastening the flexure plate to a first location of the housing and an adjustable fastener for adjustably fastening the flexure plate to a second location of the housing, the adjustable fastener configured to change at least one of a distance and an angle of the flexure plate with respect to the condenser lens as the adjustable fastener is tightened to or loosened from the housing
Data Source
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AI summary
A phosphor illumination system including a housing, a phosphor wheel, a condenser lens mounted to the housing, the condenser lens configured to condense light to an irradiation spot on the phosphor wheel and a flexure plate onto which the phosphor wheel is mounted. The flexure plate includes a fixed fastener for fixedly fastening the flexure plate to a first location of the housing and an adjustable fastener for adjustably fastening the flexure plate to a second location of the housing, the adjustable fastener configured to change at least one of a distance and an angle of the flexure plate with respect to the condenser lens as the adjustable fastener is tightened to or loosened from the housing.