Atomic Oscillator Assembly With Solder Self-Alignment
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Solution Overview
Problem
The existing manufacturing processes for atomic oscillators are complex and not suitable for mass production due to the need for precise positioning and bonding of connection members using resin adhesives, which complicates the assembly and increases production costs.
Innovation Solution
The atomic oscillator design incorporates a cross-linked structure with a support substrate, insulating film, and base, where components like the light source, gas cell, and photodetector are bonded using solder, eliminating the need for resin adhesives and allowing for self-alignment during assembly, thereby simplifying the manufacturing process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection members are fitted to the gas cell using resin adhesive bonding, then the gas cell can be supported and connected, but the manufacturing process becomes complicated and requires dedicated positioning devices
Solution Approach 1:
The patent replaces the resin adhesive bonding system with a mechanical connection system using connection members that have fitting portions inserted into grooves formed on the gas cell. This mechanical fitting eliminates the need for resin adhesives and the complex positioning processes they require, while maintaining reliable connections through precise mechanical interlocking.
Solution Approach 2:
The connection members are designed with self-alignment capabilities where the fitting portions automatically align with the grooves on the gas cell during assembly. This self-service mechanism eliminates the need for dedicated positioning devices and complex manual alignment procedures, enabling mass production while ensuring reliable connections.
2Reliability
If resin adhesive is used for bonding components, then components can be connected, but characteristic deterioration occurs due to resin adhesive gases
Solution Approach 1:
The patent extracts and removes the resin adhesive from the connection system, replacing it with a mechanical fitting mechanism. This elimination of resin adhesive completely prevents the generation of harmful resin adhesive gases, while the connection reliability is maintained through the mechanical interlocking of the fitting portions and grooves.
3Strength
If two connection members are fitted from both sides of the gas cell, then the gas cell is securely supported, but the assembly process becomes time-consuming and difficult to automate
Solution Approach 1:
The connection system is segmented into modular components: connection members with fitting portions and the gas cell with corresponding grooves. This segmentation allows for standardized, repeatable assembly operations that can be easily automated, improving productivity while maintaining the secure support function through the distributed fitting portions.
Solution Approach 2:
The grooves are pre-formed on the gas cell during manufacturing, and the fitting portions are pre-shaped on the connection members. This preliminary preparation of connection interfaces enables rapid assembly without time-consuming alignment or bonding operations, significantly improving mass production capability while ensuring strong mechanical support.
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 design enables the production of atomic oscillators with improved thermal resistance and reduced energy consumption, facilitating mass production without the need for dedicated positioning devices and preventing characteristic deterioration from resin adhesive gases.
Implementation Method 1
bonding patterns facing each other are bonded by soldering
Implementation Method 2
an insulating film is disposed between the light source and the gas cell
Data Source
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AI summary
An atomic oscillator includes a plurality of components, the components including a light source that emits excitation light, a gas cell in which an atom to be excited by the excitation light is sealed, and a photodetector that detects the excitation light transmitting through the gas cell; and a main part, wherein a part of the plurality of components are laminated in the main part. In a first component and a second component adjacent to each other of the main part, an electrically conductive film is formed on each of side surfaces of the first component and the second component; bonding patterns that are extended from the respective electrically conductive films and that face each other are formed on respective bonding surfaces facing each other of the first component and the second component; and the bonding patterns that face each other are bonded by a bonding material.