Asymmetric Dust Cap for Stable Optical Module Mounting
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Solution Overview
Problem
Optical modules with dust caps experience instability during mounting on printed boards due to the center of gravity being on the side of the dust cap, causing the lead to separate from the board, making stable placement challenging.
Innovation Solution
A dust cap and connector engagement body design where the dust cap is placed in a housing with a lead frame projecting downward, and the gravity center is closer to the lead frame than the support portion, ensuring stable placement by adjusting the housing and dust cap configuration to maintain the lead's connection during soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a dust cap is placed in the housing to prevent foreign substances from entering, then protection against foreign substances is improved, but the gravity center shifts to the dust cap side causing instability during mounting
Solution Approach 1:
The dust cap is designed with an asymmetric structure where one end is closed and the other end is open. The closed end is positioned toward the optical component side while the open end extends beyond the housing. This asymmetric configuration balances the gravity center toward the lead frame side, preventing moment generation during mounting while maintaining foreign substance protection through the closed end.
Solution Approach 2:
The dust cap extends in the longitudinal direction beyond the housing boundaries. By projecting from the housing in the longitudinal dimension, the dust cap creates a counterbalancing mass distribution that shifts the gravity center without compromising the protective function. This dimensional extension allows simultaneous achievement of protection and stability.
2Object-affected harmful factors
If the dust cap is made large enough to provide adequate protection, then protection effectiveness is improved, but the moment arm increases causing greater separation force on the lead
Solution Approach 1:
The asymmetric design with closed end toward the optical component and open end extending beyond housing creates a gravity center positioned toward the lead frame side. This positioning reduces the moment arm effect even when the dust cap has sufficient size for effective protection, thereby minimizing separation force on the lead during mounting.
3Object-affected harmful factors
If the dust cap completely covers the housing opening for maximum protection, then foreign substance prevention is improved, but access for operations and heat dissipation are reduced
Solution Approach 1:
The dust cap is segmented into a closed end portion and an open end portion. The closed end provides protection against foreign substances entering the housing, while the open end allows access for operations and heat dissipation. This segmentation enables the dust cap to simultaneously provide protection and maintain operational accessibility.
Solution Approach 2:
Instead of completely closing the housing opening, the dust cap extends longitudinally beyond the housing with an open end. This dimensional approach allows the protective function to be achieved through the closed end while maintaining access through the open end, balancing protection with operational ease.
Data Source
AI summary
A connector engagement body (1) comprises: a housing (3) from which a lead frame (9) of an electronic component (7) projects; and a heat-resistant dust cap (5) resistant to the heat generated when soldering the lead frame (9) and disposed in the housing (3) to prevent foreign substances from entering the inside of the housing (3), the center of gravity of the housing (3) and the electronic component (7) is located closer to the lead frame (9) than to a support (11) for the housing (3).