Tubular Light Source Module for Laser Diode Alignment
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Solution Overview
Problem
Conventional laser diode modules suffer from poor machining tolerances, leading to reduced illuminating efficiency and assembly accuracy, especially when multiple laser diodes are used to enhance brightness, due to deformation and alignment issues.
Innovation Solution
A light source module design featuring a tubular shell, a fixed ring, an optical element, and a light-emitting element, where the shell and fixed ring securely position the optical and light-emitting elements, enhancing concentricity accuracy and assembly precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple laser diodes are used to enhance brightness, then illumination intensity increases, but machining tolerance accumulation reduces assembly accuracy and concentricity
Solution Approach 1:
The patent merges the laser diode and lens into a single integrated holder structure, eliminating the separate lens holder and reducing the number of components. This integration prevents tolerance accumulation between multiple holders and ensures precise alignment between the laser diode optical axis and lens optical axis, thereby maintaining high assembly accuracy while using multiple laser diodes for enhanced brightness.
Solution Approach 2:
The patent segments the holder into multiple independent holding structures, each designed to precisely position a laser diode and its corresponding lens. By providing dedicated holding structures for each laser diode-lens pair, the design ensures that alignment accuracy is maintained for each individual component while allowing multiple units to be assembled with consistent precision.
2Reliability
If laser diodes are gripped and fixed by the holder structure, then positioning is achieved, but the large size of the holder causes deformation and reduces flatness
Solution Approach 1:
The holder structure is merged into a compact integrated design that combines the laser diode holder and lens holder functions. This integration reduces the overall size of the holding structure, preventing deformation and flatness issues while maintaining reliable positioning of the laser diodes through precision machining features and rigid construction.
3Quantity of substance
If the holder structure is made large to accommodate multiple laser diodes, then capacity increases, but the structure becomes frail and easily deformed
Solution Approach 1:
The patent merges the laser diode holder and lens holder into a single integrated structure, which consolidates the support function and improves structural strength. This unified design eliminates the weakness of multiple separate holders and provides a rigid framework that can accommodate multiple laser diodes without being easily deformed.
Solution Approach 2:
The holder structure is designed using materials and construction methods that provide high strength-to-weight ratio and resistance to deformation. The integrated holder employs rigid materials and reinforcement features that enable it to support multiple laser diodes while maintaining structural integrity and resistance to bending under thermal and mechanical loads.
4Ease of manufacture
If many holes are formed in the holder structure for mounting and locating, then assembly capability is provided, but structure strength is reduced
Solution Approach 1:
The patent merges the mounting and locating functions into the integrated holder structure with strategically positioned features. By combining the holder functions and using precision-machined reference surfaces and alignment features, the design achieves easy assembly capability without requiring numerous holes that would weaken the structure.
Data Source
AI summary
A light source module includes a shell, a fixed ring, an optical element, a first cover and a light-emitting element. The shell is formed as a tubular shape. The fixed ring, the optical element and the light-emitting element are all received in an inside of the shell, and the first cover is disposed at an end of the shell. In addition, the shell has a first stop part disposed in the inside of the shell, the optical element is disposed between the first stop part and the fixed ring, and the optical element is leant against the first stop part and the fixed ring. The light-emitting element is disposed between the fixed ring and the first cover, and is leant against the fixed ring and the first cover. A projection device using the source light module is also provided.