Ceramic Package Alignment via Observation Openings

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Solution Overview

Problem

Conventional package members face challenges in quantitatively deriving positional deviations between ceramic layers, which affects the accurate alignment of surface-emitting laser elements and photodiodes, leading to fluctuations in light output and inefficient auto power control in optical scanning devices.

Innovation Solution

A package member with stacked ceramic layers, where one layer has a surface-emitting laser element and the other has a photodiode, includes markings and openings for observing positional deviations, allowing for the quantitative determination of layer alignment and adjustment of the photodiode's position to ensure optimal light beam alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional package members are used without marking systems, then the structure remains simple, but positional deviation between ceramic layers cannot be quantitatively determined

Engineering Contradiction:

Improvepositional deviation detectionVSAvoidpackage structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

Marks are formed on the first ceramic layer before stacking with the second ceramic layer. This preliminary marking enables subsequent quantitative measurement of positional deviation without adding complex measurement equipment to the final assembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mark system acts as an intermediary element between the two ceramic layers, providing a reference framework that enables indirect measurement of positional deviation through observation openings in the second layer.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If ceramic layers are stacked without alignment marks, then manufacturing is simpler, but alignment accuracy between layers deteriorates

Engineering Contradiction:

Improvelayer alignmentVSAvoidstacking process

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

Alignment marks are prepared in advance on the first ceramic layer before the stacking operation. This preliminary preparation enables precise alignment during assembly without requiring complex real-time measurement equipment or skilled manual adjustment.

Inventive Principle:

Principle #10Preliminary action

3Measurement precision

If no observation openings are provided, then the ceramic layer structure remains intact, but positional deviation cannot be observed

Engineering Contradiction:

Improveposition observationVSAvoidceramic layer structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

Observation openings are created by removing material from the second ceramic layer at specific locations. This extraction enables direct visual or instrumental observation of the marks on the first layer, allowing quantitative measurement of positional deviation.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The observation openings in the second ceramic layer are positioned to align with the marks on the first layer, creating a nested observation system where the upper layer's openings provide access to the lower layer's reference features.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 configuration enables accurate auto power control and stable light output from surface-emitting laser arrays, improving the quality of images formed in optical scanning devices like color printers by ensuring precise positional alignment between ceramic layers.

Implementation Method 1

a transparent member that is tilted with respect to an output surface of the surface-emitting laser element and that reflects a part of light output from the surface-emitting laser element

Methodology Applied

Scientific EffectLight reflection: Reflection

Implementation Method 2

a photodiode that is provided to the second ceramic layer and that receives the light reflected by the transparent member

Methodology Applied

Scientific EffectPhotoelectric detection: Photoelectric Effect

Data Source

PatentUS9063004B2Package member for electronic component and optical device including the package member

Publication Date: 2015.06.23 RICOH CO LTD

AI summary

A ceramic package includes a chip mounting portion, a photodiode (PD) mounting portion, a plurality of connecting terminals, and a gold-plated portion. The chip mounting portion is a portion on which a surface-emitting laser array chip is mounted on a first ceramic layer. The PD mounting portion is provided to a second ceramic layer stacked on the positive side in a c-axis direction of the first ceramic layer. Openings are formed at four corners of the PD mounting portion. A scale is formed on a portion that can be observed through the opening of the second ceramic layer on the surface of the positive side in the c-axis direction of the first ceramic layer.