Laser Module Lead Terminal Sealing and Support for Wire Bonding
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Solution Overview
Problem
Conventional laser modules face issues with complex assembly processes, increased manufacturing costs, and defective connections due to the separate components for sealing and supporting lead terminals, which complicate the connection of conductive wires during the ultrasonic bonding process.
Innovation Solution
A laser module design that integrates an insulation member with both sealing and support functions, where the insulation member includes a seal portion that seals between the side wall and the lead terminal and an extension portion that contacts and supports the connecting portion of the lead terminal, reducing the number of components and preventing vibration during ultrasonic bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a seal member and support member are provided separately for the lead terminal, then the sealing and support functions are achieved, but the manufacturing cost increases and the assembly process becomes complicated
Solution Approach 1:
The patent combines the seal member and support member into a single integrated component. The insulation member includes both a seal portion that seals between the side wall and lead terminal, and an extension portion that extends into the housing to support the connecting portion of the lead terminal. This merging eliminates the need for separate components, reducing assembly steps and manufacturing cost while maintaining both sealing and support functions.
Solution Approach 2:
The insulation member is designed to perform multiple functions simultaneously: it provides electrical insulation, seals the opening in the side wall, and supports the connecting portion of the lead terminal. By making the insulation member multi-functional, the patent reduces the total number of components needed while achieving all necessary functions for the lead terminal assembly.
2Reliability
If a seal member and support member are provided separately for the lead terminal, then the sealing and support functions are achieved, but the assembly operation becomes complicated
Solution Approach 1:
The patent combines the seal member and support member into a single integrated component. The insulation member includes both a seal portion that seals between the side wall and lead terminal, and an extension portion that extends into the housing to support the connecting portion of the lead terminal. This merging eliminates the need for separate components, reducing assembly steps and manufacturing cost while maintaining both sealing and support functions.
3Reliability
If separate components are used for sealing and supporting the lead terminal, then the functions are achieved, but the connection accuracy of conductive wire deteriorates due to accumulation of tolerances
Solution Approach 1:
The patent combines the seal member and support member into a single integrated component. The insulation member includes both a seal portion that seals between the side wall and lead terminal, and an extension portion that extends into the housing to support the connecting portion of the lead terminal. This merging eliminates the need for separate components, reducing assembly steps and manufacturing cost while maintaining both sealing and support functions.
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 simplifies the assembly process, reduces manufacturing costs, and prevents defective connections by using a single insulation member for both sealing and supporting the lead terminal, allowing for accurate and reliable connection of the conductive wire.
Implementation Method 1
a seal portion that seals between the side wall and the lead terminal at the opening of the side wall
Implementation Method 2
an extension portion extending from the seal portion into the housing while contacting the lead terminal. The extension portion of the insulation member includes a support portion that is in contact with the connecting portion of the lead terminal and supports the connecting portion
Implementation Method 3
In the wire bonding process using ultrasonic waves, ultrasonic vibration generated by an ultrasonic generator is transmitted to a tip of a tool of a wire bonding apparatus. A conductive wire is connected to a connecting portion of a lead terminal by a load with which the tip of the tool presses the conductive wire against the connecting portion of the lead terminal and friction and hence heat due to the ultrasonic vibration.
Data Source
AI summary
A laser module includes an optical fiber, a laser device, an optical system, a housing, a lead terminal, a conductive wire, and an insulation member. The laser device emits a laser beam. The optical system couples the laser beam, emitted from the laser device, to the optical fiber. The housing includes a base plate on which the laser device is fixed and a side wall that includes an opening. The lead terminal extends from an outside of the housing through the opening of the side wall into the housing. The conductive wire electrically connects a connecting portion of the lead terminal, located within the housing, to the laser device. The insulation member includes a seal portion and an extension portion.