Lead Frame Protective Leads Prevent Misregistration in Optical Coupling
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Solution Overview
Problem
Existing optical coupling parts face challenges in forming continuous three-dimensional electric wiring, which is difficult to achieve due to the complexity of mechanically holding optical fibers and connecting them to photoelectric conversion units efficiently.
Innovation Solution
A lead frame with a lead pattern and protective leads is inserted into a molded body, allowing for easy formation of three-dimensional electric wiring by moderating the resin flow and reducing forces acting on the lead pattern during the molding process, preventing misregistration and deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If three-dimensional electric wiring is formed on the object surface, then the flexibility of the coupling position is enhanced, but it is difficult to form such wiring continuously
Solution Approach 1:
The patent transitions from planar two-dimensional wiring to three-dimensional wiring by extending electric wiring patterns onto the side faces of the molded body in addition to the top surface. This dimensional expansion allows flexible coupling positions at various angles and locations, enabling adaptability while maintaining manufacturability through continuous molding processes.
2Extent of automation
If resin is poured for molding the molded body, then the lead frame is attached to the front end face, but the force acting on the lead pattern causes misregistration and deformation
Solution Approach 1:
The patent applies preliminary protective measures by providing protective leads at both outside positions of the lead pattern before the molding process. These protective leads act as reinforcement structures that prevent misregistration and deformation of the lead pattern when resin is poured and force acts on the lead frame during insert molding, thereby maintaining manufacturing precision while enabling automated molding.
3Manufacturing precision
If protective leads are provided on both outsides of the lead pattern, then the flow of resin is moderated and misregistration is prevented, but the device complexity increases
Solution Approach 1:
The protective leads serve multiple functions simultaneously: they reinforce the lead pattern to prevent misregistration and deformation, moderate the flow of resin during molding, and provide structural support for the lead frame. By making the protective leads multi-functional, the patent achieves improved manufacturing precision without proportionally increasing device complexity, as the same structural elements perform multiple protective and supportive roles.
Data Source
AI summary
When a resin 59 to form a molded body 20 is poured and a lead frame 30 is attached to a front end face 21 of the molded body 20 by insert molding, protective leads 32 provided on both outsides of a lead pattern 31 of the lead frame 30 moderate the flow of the resin 59 and the force acting on the lead pattern 31 is decreased, so that misregistration of the lead pattern 31 can be prevented. Accordingly, the inserted and molded lead frame 30 can be wired on the front end face 21 of the molded body 20 for easily accomplishing three-dimensional electric wiring.