UV-curable fiber optic sensor structure and its manufacturing method

Abstract

This invention relates to a UV-curable fiber optic sensor structure and its manufacturing method, aiming to optimize the manufacturing process of traditional fiber optic sensors and reduce costs while maintaining detection accuracy. The structure includes: a main mold with a curing lamp assembly, a silicone mold placed within the main mold, and UV adhesive injected into the molding groove of the silicone mold. The manufacturing process includes the following steps: First, a silicone mold with 75% light transmittance is placed into the main mold, which has a molding groove. Then, an equal amount of UV adhesive with up to 95% light transmittance is injected into the molding groove. A clamp is used to precisely place the fiber optic cable 2 mm deep within the UV adhesive. Subsequently, the curing lamp assembly on the main mold is activated and irradiated for 5 seconds at a time, allowing the UV adhesive to cure and form a collimating lens with the fiber optic cable. The front end of this molded part has a light-transmitting surface. Finally, the front end of the collimating lens is bonded to a metal connector to complete the assembly. This invention utilizes high-transmittance UV adhesive and a simple mold design, enabling the collimating lens product to maintain precise detection functions while reducing the number of parts and cumbersome assembly steps, ultimately effectively reducing costs.

Description

Technical Field

[0001] This invention relates to a structure and manufacturing method of a UV-curable fiber optic sensor, particularly a method that uses UV adhesive in conjunction with a curing lamp to coat the fiber optic cable with a collimating lens with high light transmittance, and then bondes it with a metal connector, thereby simplifying the number of conventional parts and the cumbersome manufacturing process. Prior Technology

[0002] Most commercially available fiber optic sensors today combine the advantages of fiber optic transmission and optical focusing due to their built-in lens focusing design, resulting in high sensitivity and accuracy. Since focusing also significantly extends the detection distance, they are widely used in fields such as industrial inspection and medical diagnosis.

[0003] However, in the process of manufacturing and installing the structure, very precise alignment mechanisms and techniques are required. Since the lens is built-in, when used in harsh environments, it is necessary to select suitable lens materials or take additional protective measures, which leads to higher costs, more parts to be manufactured, or overly complicated steps.

[0004] Therefore, fiber optic sensors urgently need a manufacturing method that can effectively simplify the number of manufacturing parts and cumbersome steps, thereby reducing manufacturing costs, while maintaining detection accuracy and increasing production volume. Summary of the Invention

[0005] One embodiment of the present invention provides a UV-curable fiber optic sensor structure, which mainly utilizes UV adhesive and silicone mold to place the fiber optic cable inside the UV adhesive and then use a curing lamp to illuminate and shape it, and then bond it with a metal connector. This can significantly reduce the number of parts and simplify the previously cumbersome manufacturing process, thereby reducing manufacturing costs while maintaining the original precision sensing function.

[0006] The present invention provides a UV-curable fiber optic sensor structure, comprising: a main mold having a curing lamp assembly; a silicone module being fitted into the main mold, the silicone module having a molding groove; an equal amount of UV adhesive being injected into the molding groove; an optical fiber being placed 2 mm deep within the molding groove; and a collimating lens being formed by periodically irradiating the UV adhesive with the curing lamp assembly; and finally, the front end of the collimating lens being bonded and assembled with a metal connector.

[0007] The present invention relates to a UV-curable fiber optic sensor structure and its manufacturing method, comprising: first, positioning a main mold equipped with a curing lamp assembly in an appropriate position; then, fitting a silicone mold with 75% light transmittance into the main mold; the silicone mold also having a molding groove; after continuously injecting an equal amount of UV adhesive with 95% light transmittance into the molding groove; then, placing an optical fiber cable with a clamp into the molding groove at a depth of 2 mm; since the optical fiber cable is encased in the UV adhesive, after being irradiated by the curing lamp assembly at a timed interval of 5 seconds, a collimating lens is formed; the front end of this collimating lens forms a molding surface with light transmittance characteristics; and then, the front end of the collimating lens is bonded and assembled with a metal connector.

[0008] To enable your review committee to have a better understanding of the technical features and effects of the present invention, preferred embodiments are illustrated and accompanied by detailed descriptions, as follows. Simple Explanation of the Diagram

[0009] [Figure 1] is a perspective view of the present invention.

[0010] [Figure 2] is a flowchart of the implementation steps of the present invention (I).

[0011] [Figure 3] is a flowchart (II) of the implementation steps of the present invention.

[0012] [Figure 4] is a three-dimensional schematic diagram of the implementation steps of the present invention based on Figures 2 and 3.

[0013] [Figure 5] is a flowchart of the implementation steps of the present invention (III).

[0014] Figure 6 is a flowchart of the implementation steps of the present invention (IV).

[0015] [Figure 7] is a three-dimensional schematic diagram of the implementation steps of the present invention based on Figures 5 and 6.

[0016] Figure 8 is a flowchart of the manufacturing method of the present invention. Implementation

[0017] Generally, according to the present invention, the preferred feasible embodiment, and in conjunction with Figures 1 to 7, a detailed description is provided to enhance understanding of the present invention. The present invention is a UV-curable fiber optic sensor structure, comprising: a main mold (10) having a curing lamp assembly (11) configured to cooperate with it, the curing lamp assembly (11) can also be disassembled or externally connected according to actual on-site operation requirements, and is not limited thereto; a silicone mold (20) configured to cooperate within the main mold (10), and the silicone mold (20) having a molding groove (21), the light transmittance of the silicone mold (20) being 75%; a UV adhesive (30) whose main components are composed of oligomers, reactive monomers, and photoinitiators, the aforementioned oligomers typically being epoxy acrylates, urethane acrylates, or polyester acrylates. One of the acrylates is a reactive monomer added to the aforementioned oligomer to reduce viscosity and increase ease of use. The photoinitiator is used to absorb the energy of ultraviolet light to form free radicals or cationic groups, causing the monomer and oligomer to undergo a chain polymerization reaction, thereby allowing the UV adhesive (30) to cure. The UV adhesive (30) is also called ultraviolet curing adhesive. After an equal amount of UV adhesive (30) is injected into the molding tank (21), an optical fiber (40) is fixedly positioned in the molding tank (21) with a fixture at a depth of 2 mm. After the UV adhesive (30) is irradiated with the curing lamp (11) for 5 seconds at a time to form a collimating lens (31), the transmittance of the aforementioned UV adhesive (30) is 95%. This can effectively improve the problem of light attenuation and replace the conventional focusing structure. It can also maintain calibration accuracy in mass production. The irradiation time of the aforementioned curing lamp (11) is determined by the amount and area of ​​UV adhesive (30) used in the molding tank (21). The optimal number of seconds for calculating the curing rate can be adjusted according to production needs and is not limited to this. A shaping surface (32) is formed at the front end of the collimating lens (31). The shaping surface (32) has light-transmitting characteristics and can correspond to the design changes in the shaping groove (21). For example, the shaping surface (32) shown in Figures 2 to 7 is a curved surface. It can also be changed to a rhombus, rectangle, square, circle, etc., or other shapes with light-concentrating effect through the shaping groove (21). Therefore, it is not limited to this. Finally, the front end of the collimating lens (31) is bonded and assembled with a metal connector (50).

[0018] The following is a further explanation of the manufacturing method of the embodiment of the present invention. Please refer to Figure 8 for further details. The method includes: Step 1: First, a main mold (10) equipped with a curing lamp assembly (11) is positioned in an appropriate position. Then, a silicone mold (20) with a light transmittance of 75% is placed in the main mold (10). A molding groove (21) is also provided in the silicone mold (20). Step 2: After injecting an equal amount of UV adhesive (30) with a light transmittance of 95% into the molding groove (21), an optical fiber (40) is placed in the molding groove (21) with a fixture at a depth of 2 mm. Step 3: Since the optical fiber (40) is encased in the UV adhesive (30), after the UV adhesive (30) is irradiated by the curing lamp group (11) for 5 seconds at a time, a collimating lens (31) is formed. The front end of the collimating lens (31) forms a shape surface (32) with light transmission characteristics. Step 4: The front end of the collimating lens (31) is then bonded and assembled with a metal connector (50).

[0019] In summary, the present invention has a UV-curable fiber optic sensor structure and its manufacturing method. By using a UV adhesive (30) with 95% transmittance and a silicone mold (20) with 75% transmittance, the fiber optic cable (40) is placed inside the UV adhesive (30) and then continuously illuminated by the curing lamp group (11) to form the collimating lens (31). It is then further bonded with a metal connector (50). This can significantly reduce the number of parts and simplify the previously cumbersome manufacturing process, thereby reducing manufacturing costs while maintaining the original precision sensing function.

[0020] (10): Main mold

[0021] (11): Curing lamp assembly

[0022] (20): Silicone mold

[0023] (21): Shaping groove

[0024] (30): UV adhesive

[0025] (31): Collimating lens

[0026] (32): Shape surface

[0027] (40): Fiber optic cables

[0028] (50): Metal connector

Claims

1. A UV-curable fiber optic sensor structure comprising: a main mold (10) having a curing lamp assembly (11); a silicone mold (20) disposed within the main mold (10), wherein the silicone mold (20) has a molding groove (21), characterized in that: an equal amount of UV adhesive (30) is injected into the molding groove (21), an optical fiber (40) is placed 2 mm deep within the molding groove (21), and the UV adhesive (30) is periodically irradiated by the curing lamp assembly (11) to form a collimating lens (31), and a light-transmitting molding surface (32) is provided at the front end of the collimating lens (31) to correspond to the design changes within the molding groove (21), so that the front end of the collimating lens (31) is bonded and assembled with a metal connector (50).

2. The UV-cured fiber optic sensor structure as described in claim 1, wherein the curing lamp assembly (11) is irradiated for a period of 5 seconds.

3. The UV-curable fiber optic sensor structure as described in claim 1, wherein the silicone mold (20) has a light-transmitting feature with a light transmittance of 75%.

4. The UV-curable fiber optic sensor structure as described in claim 1, wherein the UV adhesive (30) has a light transmittance of 95%.

5. A manufacturing method using a UV-curable fiber optic sensor structure as described in any one of claims 1 to 4, comprising: Step 1: First, position a main mold (10) equipped with a curing lamp assembly (11) in an appropriate position, and then place a silicone mold (20) with a light transmittance of 75% inside the main mold (10). The silicone mold (20) also has a molding groove (21). Step 2: After injecting an equal amount of UV glue (30) with a light transmittance of 95% into the molding groove (21), place an optical fiber (40) with a clamp into the molding groove (21) at a depth of 2 mm. Step 3: Since the optical fiber (40) is covered in the UV glue (30), after the UV glue (30) is irradiated by the curing lamp assembly (11) for 5 seconds at a time, a collimating lens (31) is formed. The front end of the collimating lens (31) forms a molding surface (32) with light transmittance characteristics. Step 4: Then, the front end of the collimating lens (31) is bonded and assembled with a metal connector (50).

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