Resin Holder for Optical Alignment in Vehicle HUD
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Solution Overview
Problem
Current light reflection devices for mobile objects, such as vehicles, face challenges in maintaining precise alignment and stability of optical elements due to differences in thermal expansion between the housing and circuit boards, leading to potential image quality issues and mechanical stress.
Innovation Solution
A light reflection device with a holder that allows the reflector to change size while maintaining alignment, using a holder with similar thermal expansion characteristics to the housing, and employing an adhesive with UV curing properties to secure the optical scanning chip and modulation element, reducing stress and ensuring precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixation member is used to connect the housing and circuit board, then the relative positions of optical elements and imaging device are maintained, but thermal expansion differences cause mechanical stress and potential misalignment
Solution Approach 1:
A holder made of resin material is introduced as an intermediary component between the housing and the optical scanning device. This holder serves as a buffer that absorbs thermal expansion differences, preventing direct stress transmission while maintaining precise alignment of optical elements through its positioning structure.
Solution Approach 2:
The holder is constructed from resin material that provides both mechanical support and thermal buffering properties. This composite approach combines the structural integrity needed for positioning with the thermal flexibility required to accommodate expansion differences between metal housing and circuit board components.
2Strength
If adhesive is used to fix the optical scanning device, then the device is securely held, but thermal expansion causes stress concentration and potential damage
Solution Approach 1:
The resin holder acts as a stress-distributing intermediary between the adhesive bonding interface and the optical scanning device. It spreads thermal stresses over a larger area and reduces peak stress concentrations at the adhesive bonds, preventing damage while maintaining secure attachment.
Solution Approach 2:
The holder's resin material properties are selected to match thermal expansion characteristics, creating a gradual transition in thermal parameters from the housing to the optical device. This parameter matching reduces abrupt stress changes and protects the adhesive bonds from thermal shock.
3Manufacturing precision
If the holder restricts reflector movement completely, then alignment precision is maintained, but thermal expansion is constrained causing internal stress
Solution Approach 1:
The holder employs a dynamic restraint mechanism where the positioning structure provides lateral constraints to maintain alignment while allowing longitudinal expansion. This selective flexibility enables the reflector to move with thermal expansion while preventing misalignment that would degrade optical performance.
Solution Approach 2:
Different regions of the holder provide different degrees of constraint: the positioning features maintain precise lateral alignment of the reflector, while the bonding interface allows longitudinal thermal expansion. This localized differentiation of constraint quality resolves the contradiction between precision and stress.
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 maintains high stability and precision in the alignment of optical elements, reducing image distortion and mechanical stress, and ensures consistent image quality despite temperature changes.
Implementation Method 1
employing an adhesive with UV curing properties to secure the optical scanning chip and modulation element
Implementation Method 2
a reflector configured to reflect the irradiation light emitted from the light source
Implementation Method 3
a front windshield configured to reflect the irradiation light diverged and projected through the screen
Data Source
AI summary
A light reflection device is provided with a light source configured to emit irradiation light, a reflector configured to reflect the irradiation light emitted from the light source, a housing, and a holder attached to the housing to hold the reflector. The holder is configured to restrict a movement of the reflector and allows a size of the reflector to change in contrast with the holder. A mobile object is provided with the light reflection device, a screen on which an image is formed by the irradiation light reflected by the reflector, a front windshield configured to reflect the irradiation light diverged and projected through the screen, and an imaging optical system configured to project the irradiation light emitted from the screen toward the front windshield.