Vehicle Optical Device Flexible Rigid Aligning Mechanism
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing optical devices for vehicles face challenges in aligning optoelectronic devices with optical elements efficiently and cost-effectively, particularly in compensating for manufacturing tolerances and thermal expansion, which affects the precision and reliability of the alignment.
Innovation Solution
The optical device employs a dual-element aligning system with flexible and rigid components that exert pressure forces to align optoelectronic devices with optical elements, allowing for zero-tolerance alignment in one direction and accommodating degrees of freedom in other directions through lateral displacement within recesses, enabling precise positioning across multiple axes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single protrusion and recess reference point system is used for alignment, then the device complexity is reduced, but the manufacturing precision and alignment accuracy deteriorate due to inability to compensate for tolerances
Solution Approach 1:
The alignment device is segmented into multiple elements (first aligning element on optical device, second aligning element on optical element) that work together within a recess system. This segmentation allows each element to perform specific functions (constraining, positioning) while collectively achieving high alignment precision that a single reference point cannot provide.
Solution Approach 2:
The recess structure acts as an intermediary element between the aligning devices and the components being aligned. It provides a controlled interface that guides and constrains the alignment process, enabling precise positioning while compensating for manufacturing tolerances through its geometric design.
2Manufacturing precision
If rigid alignment elements are used, then the manufacturing precision is improved through stable positioning, but the adaptability to thermal expansion and tolerance compensation deteriorates
Solution Approach 1:
The alignment system incorporates dynamic characteristics through the interaction of rigid positioning elements with compliant recess structures. The rigid elements provide stable reference positions, while the recess geometry allows for controlled movement and adjustment, enabling the system to adapt to thermal expansion and manufacturing variations while maintaining positioning accuracy.
Solution Approach 2:
The system accommodates parameter changes (thermal expansion, tolerance variations) through the geometric design of the recess structures. The recesses are designed with specific dimensions and orientations that allow components to expand or shift within acceptable ranges while maintaining proper alignment, effectively compensating for parameter changes without requiring active adjustment mechanisms.
3Manufacturing precision
If multiple aligning devices with flexible and rigid elements are used, then the manufacturing precision and alignment accuracy are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
Multiple alignment functions are merged into integrated recess structures that are formed as part of the component manufacturing process. The recesses combine positioning, constraining, and guiding functions in single geometric features, reducing the number of separate alignment devices needed while maintaining high alignment accuracy.
Solution Approach 2:
The recess structures serve multiple functions simultaneously: they provide positioning references, constrain component movement, guide assembly operations, and compensate for tolerances. This multi-functionality reduces the overall complexity of the alignment system compared to using separate dedicated devices for each function.
4Ease of manufacture
If conventional alignment methods are used, then the ease of manufacture is improved, but the reliability of alignment under varying temperatures deteriorates
Solution Approach 1:
The alignment system is designed with explicit consideration of thermal expansion effects. The recess structures and aligning element dimensions are calculated to accommodate expected thermal growth, ensuring that components remain properly aligned across the operating temperature range. The geometry allows for controlled expansion while maintaining functional alignment.
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 solution ensures precise and cost-effective alignment of optical and optoelectronic components, maintaining zero tolerance across varying temperatures and material expansions, enhancing the safety and efficiency of vehicle lighting systems.
Implementation Method 1
a first aligning element of a first aligning device of the at least one aligning device is arranged on the optical device and is formed as a first flexible element that exerts a pressure force to the first recess
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An optical device (200, 800) for a vehicle (100) is described. The optical device (200, 800) comprises: - a circuit board (202) on which at least one optoelectronic device (210 to 220) and at least one recess (250) are arranged, - an optical element (300) that is arranged on the at least one optoelectronic device (210 to 220), and - at least one aligning device (400, 880), each aligning device (400, 880) comprising at least two aligning elements (402, 404), wherein the at least one aligning device (400, 880) aligns the optical device (300,) with regard to the at least one optoelectronic device (210) by engagement within the at least one recess (250), wherein a first aligning element (402, 902) of a first aligning device of the at least two aligning devices (400) is arranged on the optical element (300) and is formed as a first flexible element that exerts a pressure force to a first recess (250) of the at least one recess (250), and wherein a second aligning element (404, 904) of the first aligning device (400, 880) is arranged on the optical element (300) and formed as a rigid element within the first recess (250).