Eccentric Diffraction Layer Flange for Spectroscopy Module Mold Release

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Solution Overview

Problem

The challenge is to stabilize the forming of finer and thinner diffraction grating patterns in spectroscopic modules to enhance reliability, as they are more prone to peeling and damage during the mold release process.

Innovation Solution

A spectroscopic module design featuring a diffraction layer with a flange along its periphery, formed eccentric to the center, and a reflection layer that is circular and integrated within the diffraction grating pattern, along with a protective layer to prevent peeling and improve sensitivity, and a manufacturing method that releases the mold earlier from the side with higher adherence to prevent damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the diffraction grating pattern is made finer and thinner to reduce the size of the spectroscopic module, then the size of the module is reduced, but the diffraction layer becomes more prone to peeling and damage during mold release

Engineering Contradiction:

Improvesize of spectroscopic moduleVSAvoidstability of diffraction grating pattern forming

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent applies segmentation by dividing the mold release process into two distinct stages: first releasing the mold from the diffraction layer, then releasing from the spectroscopic unit. This sequential release prevents the thin diffraction layer with fine grating patterns from peeling or damaging during a single simultaneous release, thereby resolving the contradiction between miniaturization and manufacturing reliability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements preliminary action by performing the first mold release from the diffraction layer before the second release from the spectroscopic unit. This preliminary release step protects the fragile thin diffraction layer and fine grating patterns from damage, enabling successful miniaturization while maintaining manufacturing stability

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If the mold is released from the diffraction grating pattern side, then the release process is simplified, but the diffraction layer and diffraction grating pattern are damaged due to high adherence

Engineering Contradiction:

Improvemold release processVSAvoidintegrity of diffraction grating pattern

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent segments the mold release process into two separate operations: first releasing from the diffraction layer, then releasing from the spectroscopic unit. This prevents the diffraction grating pattern from being damaged during release while still achieving complete mold removal, resolving the contradiction between ease of manufacture and manufacturing precision

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent performs the preliminary release from the diffraction layer before releasing from the spectroscopic unit. This preliminary action protects the adherent diffraction grating pattern from damage while maintaining an efficient two-stage release process, balancing ease of manufacture with pattern integrity

Inventive Principle:

Principle #10Preliminary action

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 stabilizes the formation of the diffraction grating pattern, reduces individual module variations, and enhances sensitivity by preventing peeling and damage during mold release, while allowing for accurate inspection and improved light utilization efficiency.

Implementation Method 1

a diffraction layer (6) formed along the curved surface (3a)... The spectroscopic unit (4) has a diffraction layer (6) formed along the curved surface (3a)... for dispersing the light incident on the main unit

Methodology Applied

Scientific EffectDiffraction: Diffraction

Implementation Method 2

a reflection layer (8) formed on the outer surface (6b) of the diffraction layer (6)... the reflection layer (8) formed on the other side of the diffraction layer

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS9797773B2Spectroscopy module and manufacturing method therefor

Publication Date: 2017.10.24 HAMAMATSU PHOTONICS KK

AI summary

In a spectroscopic module 1, a flange 7 is formed integrally with a diffraction layer 6 along a periphery thereof so as to become thicker than the diffraction layer 6. As a consequence, at the time of releasing a master mold used for forming the diffraction layer 6 and flange 7, the diffraction layer 6 formed along a convex curved surface 3a of a main unit3 can be prevented from peeling off from the curved surface 3a together with the master mold. A diffraction grating pattern 9 is formed so as to be eccentric with respect to the center of the diffraction layer 6 toward a predetermined side. Therefore, releasing the mold earlier from the opposite side of the diffraction layer 6 than the predetermined side thereof can prevent the diffraction layer 6 from peeling off and the diffraction grating pattern 9 from being damaged.