Silicone Torsional Hinge Laser Scanner for Friction-Free Scanning
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Solution Overview
Problem
Conventional laser scanning mechanisms, such as shaft-based, silicone hinge-based, and flipper-based systems, face issues like friction-related instability, scan motion imprecision, and high G-force sensitivity, leading to unreliable performance and increased complexity.
Innovation Solution
A silicone frame with torsional hinges forms a virtual axis for the scan mirror and permanent magnet, providing symmetric resonant oscillation and returning forces, integrated motion limiters for stability, and a simplified assembly process, replacing traditional shaft-based systems with a more reliable and efficient torsional-based laser scanning module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shaft-based scanning mechanisms are used, then scanning function is achieved, but friction-related uncertainty and reliability problems occur
Solution Approach 1:
The patent replaces the traditional shaft-based mechanical scanning mechanism with a silicone hinge-based mechanism. The silicone hinge eliminates friction-related issues by using the elastic deformation of the silicone material to provide return force, rather than relying on mechanical shafts and magnets that generate friction and instability.
Solution Approach 2:
The patent changes the material parameter from rigid mechanical materials (shaft, magnet) to flexible silicone material. This parameter change allows the scanning mechanism to operate without friction, using the elastic properties of silicone to provide both the scanning motion and the return force.
2Reliability
If silicone hinge-based scanning assemblies are used, then friction issues are avoided, but scan motion imprecision occurs due to lack of fixed scanning axis
Solution Approach 1:
The patent segments the scanning mechanism into distinct functional components: the silicone hinge provides elastic deformation for motion, the scan mirror is mounted on a separate rotor structure, and a fixed scanning axis is established through the hinge attachment points. This segmentation allows each component to perform its specific function while maintaining overall precision.
Solution Approach 2:
The patent introduces an intermediary rotor structure that mounts both the scan mirror and permanent magnet. This rotor structure acts as a mediator between the silicone hinge's elastic deformation and the scan mirror's precise rotation, allowing the flexible hinge to provide motion while the rigid rotor ensures precise scanning along a fixed axis.
3Stability of the object's composition
If additional motion limiters are added to prevent excessive motion under high G forces, then motion control is improved, but device complexity increases
Solution Approach 1:
The patent merges the motion limiting function into the existing rotor structure and silicone hinge assembly. The rotor structure itself serves as the motion limiter through its physical design and attachment to the silicone hinge, eliminating the need for separate motion limiter components and reducing overall assembly complexity.
Solution Approach 2:
The rotor structure serves multiple functions: it mounts the scan mirror, holds the permanent magnet, provides a fixed scanning axis, and acts as a motion limiter under high G forces. This multi-functionality reduces the number of separate components needed and simplifies the overall assembly.
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 solution achieves stable and precise scanning with reduced power consumption, minimal part-to-part variation, and enhanced resistance to contaminants and environmental factors, enabling longer scanning ranges and easier integration into various products.
Implementation Method 1
the torsion posts in the silicone frame function as springs which generate returning forces to the scan mirror and magnet rotor subassembly
Implementation Method 2
when the rotor subassembly is rotated about the virtual scan axis by forces generated by an electromagnetic coil structure and acting on the permanent magnet
Data Source
AI summary
A laser scanning module employs a scan mirror and magnet rotor subassembly supported by a stationary stator structure. The scan mirror and magnet rotor subassembly includes: a silicone frame having a pair of silicone torsional hinges (i.e. posts) aligned along a scan axis and a supported by a pair of support elements associated with the stator structure, to support the scan mirror and magnet rotor subassembly. When the scan mirror and magnet rotor subassembly is rotated about its scan axis, by forces generated by an electromagnetic coil structure acting on the permanent magnet mounted on silicone frame, the silicone torsional hinges are elastically distorted and generate linear restoring forces which return the rotor subassembly back to its home position about the scan axis.