Halbach Mirror Module Assembly Without Adhesive Magnet Bonding
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Solution Overview
Problem
The use of adhesive resin to bond multiple magnets in a Halbach array for an optical module leads to potential separation and increased workload and costs, affecting reliability.
Innovation Solution
An optical module design with a magnet portion having a Halbach structure, supported by a package with a bottom wall, side wall, and restriction portion, which restricts movement of magnets without adhesive resin, ensuring they remain integrated and efficient magnetic force utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive resin is used to bond multiple magnets in a Halbach array, then the magnets can be assembled together, but the bonding interface may peel off and magnets may separate, reducing reliability
Solution Approach 1:
The patent replaces the chemical bonding system (adhesive resin) with a mechanical constraint system (package structure with positioning protrusions and recesses). The package includes a body with a magnet accommodating cavity and positioning protrusions that mechanically constrain the magnets, eliminating the need for adhesive resin and thereby preventing bonding interface peeling and magnet separation.
2Ease of manufacture
If adhesive resin is used to bond multiple magnets, then the magnets can be fixed together, but the workload and manufacturing costs increase
Solution Approach 1:
The patent merges the magnet fixation function into the package structure itself. The positioning protrusions and recesses are integrated features of the package body, combining the packaging and magnet assembly functions into a single component. This eliminates the need for separate adhesive application processes and reduces manufacturing complexity.
3Use of energy by moving object
If magnets are closely positioned to the movable mirror portion, then magnetic force utilization is improved, but the magnets may move or separate without proper constraints
Solution Approach 1:
The patent implements preliminary action by pre-positioning the magnets within the package cavity using positioning protrusions and recesses before the actual operation. The magnets are constrained in advance to prevent any movement or separation, ensuring both close positioning for efficient magnetic force utilization and stable position throughout 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
Improves reliability and reduces costs by maintaining magnet integrity and optimizing magnetic force utilization, while allowing precise positioning and efficient coil placement.
Implementation Method 1
a magnet portion (50) having an upper surface (50a), a bottom surface (50b), and a side surface (50s) extending from the upper surface to the bottom surface, and configured to generate a magnetic field acting on the movable mirror portion (10)
Implementation Method 2
The magnet portion (50) has a Halbach structure including a first magnet (51) and a pair of second magnets (52, 53)
Data Source
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AI summary
An optical module includes a mirror unit having a movable mirror portion, a magnet portion configured to generate a magnetic field acting on the movable mirror portion, and a package accommodating the magnet portion. The magnet portion has a Halbach structure including a first magnet applied with a force in a first direction, and a second magnet applied with a force in a second direction. The package has a bottom walls portion, a side wall portion, and a restriction portion configured to restrict movement of the second magnet in the second direction. The movable mirror portion is disposed in a space formed by the restriction portion.