Au-Sn Prism Bonding for High-Accuracy Optical Assembly
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Solution Overview
Problem
In optical devices, particularly those using high-output laser diodes, the positional accuracy of prisms is compromised due to adhesive agents softening and solder melt flow, leading to displacement and reduced assembly workability and increased costs.
Innovation Solution
A prism with an adhesive film featuring alternating Au and Sn layers, which are alloyed during heating, providing enhanced positional accuracy and joining strength without melting, thus eliminating the need for solder and improving assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If adhesive agent including resin is used to join prism, then assembly workability is improved, but positional accuracy deteriorates due to softening and displacement
Solution Approach 1:
The adhesive film undergoes parameter change through phase transition during heating, transforming from a solid state with high strength to a molten state that enables displacement, and then solidifying to fix the prism in its corrected position. This dynamic parameter change allows the adhesive to provide both ease of assembly and positional accuracy.
Solution Approach 2:
The adhesive film transitions from a static rigid structure to a dynamic system that can flow and adapt during heating, allowing the prism to be repositioned for optimal alignment, then returns to a static state to maintain the achieved position with high precision.
2Strength
If solder is used to join prism, then joining strength is improved, but positional accuracy deteriorates due to melt flow and displacement
Solution Approach 1:
The adhesive film utilizes controlled parameter changes through temperature-dependent phase transition, becoming molten at elevated temperatures to allow positioning adjustments, then solidifying at lower temperatures to maintain precise position with solder-like strength without the harmful melt flow effects.
3Power
If high-output laser diode is used, then light emission performance is improved, but thermal effects worsen causing adhesive softening and displacement
Solution Approach 1:
The adhesive film is designed with a specific melting point that allows it to undergo controlled phase transition during a heating process, temporarily becoming fluid to enable prism repositioning in response to thermal effects, then solidifying to maintain positional accuracy under the thermal load from high-power laser operation.
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
The solution effectively enhances the positional accuracy of prisms in optical devices, improves assembly workability, and reduces costs by preventing adhesive film melting and displacement, while maintaining reliability and reflectance.
Implementation Method 1
the second layer portion including at least one of an Au layer or an Sn layer... the Au layer and the Sn layer are preferably alternately stacked... an Au—Sn layer including an alloy of Au and Sn be provided between the Au layer and the Sn layer
Data Source
AI summary
A prism is provided with which the positional accuracy can be effectively enhanced. The prism includes: a prism body 2 having a bottom surface 2a and an inclined surface 2b connected to the bottom surface 2a; and an adhesive film 3 provided on the bottom surface 2a, the adhesive film 3 including a first layer portion positioned on a side facing the prism body 2 and a second layer portion 6 including at least one of an Au layer or an Sn layer, the first layer portion 5 and the second layer portion 6 directly or indirectly stacked.