Scan element for use in scanning light and method of making the same
A scan element includes a bobbin having a central axis about which is wound an electromagnetic wire coil and having a flange oriented generally transverse to the central axis. At least one elastomeric support has a first end coupled to the flange. A permanent magnet has first and second surfaces, a central axis, and a magnetization direction oriented generally transverse to the central axis of the permanent magnet. The magnet is supported by a second end of the elastomeric support. A mirror has a central axis and is mounted on the second surface of the magnet. The central axes of the mirror and magnet are coaxial with the central axis of the bobbin. The elastomeric support provides a return force when the magnet and the mirror are rotated at an angle from the central axis during energization of the electromagnetic wire coil.
1. A scan element for use in scanning light from a light source, said scan element comprising:
(a) a bobbin having a central axis about which is wound an energizable electromagnetic wire coil, said bobbin including a flange oriented generally transverse to the central axis of said bobbin;
(b) an elastomeric support having first and second ends, wherein said first end is coupled to the flange of said bobbin;
(c) a permanent magnet having a central axis and a magnetization direction, wherein said permanent magnet is embedded within said elastomeric support adjacent to the second end of said elastomeric support, wherein the central axis of said permanent magnet is generally coaxial with the central axis of said bobbin, and wherein the magnetization direction of said permanent magnet is oriented generally transverse to the central axis of said permanent magnet;
(d) a mirror having a central axis and being mounted on the second end of said elastomeric support, wherein the central axis of said mirror is generally coaxial with the central axes of said bobbin and said permanent magnet,
wherein said elastomeric support provides a return force when said permanent magnet and said mirror are rotated at an angle from the central axis of said bobbin during energization of the electromagnetic wire coil.
2. The scan element of claim 1 , wherein said elastomeric support has an intermediate portion between the first and second ends, and wherein the intermediate portion has a cross-sectional area smaller than a cross-sectional area of said first and second ends.
3. The scan element of claim 1 , wherein said elastomeric support is formed from a silicone room temperature vulcanization (RTV) resin.
4. The scan element of claim 1 , wherein said elastomeric support is generally coaxially aligned with the central axes of said bobbin, said permanent magnet, and said mirror.
5. The scan element of claim 1 , wherein said elastomeric support has a cross-section of one of a rectangle, a circle, and an ellipse.
6. The scan element of claim 1 , wherein the permanent magnet is coupled to said mirror.
7. A method of forming a scan element, said method comprising:
(a) providing a bobbin having a flange, said flange having a generally flat surface;
(b) forming an elastomeric support having first and second ends, wherein said first end is coupled to the surface of said flange;
(c) embedding a magnet within said elastomeric support adjacent said second end; and
(d) mounting a mirror to the second end of said elastomeric support.
8. The method of claim 7 , wherein the step of forming said elastomeric support includes patterning and hardening a molding material and adhering the first end to the surface of said flange.
9. The method of claim 7 , wherein the step of forming said elastomeric support includes patterning a molding material and placing a predetermined amount of molding material in contact with the surface of said flange prior to hardening said molding material.
10. The method of claim 7 , further comprising:
(e) coupling said mirror to said magnet.