Light Sensor Alignment Structures for Precision Mounting
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Solution Overview
Problem
The alignment of light sensors with apertures in electronic devices is often challenging, leading to diminished signal strength due to misalignment, which affects the performance of proximity and ambient light sensors.
Innovation Solution
An alignment system comprising cameras, actuating members, and computing equipment is used to optically align light sensors with apertures, allowing for precise positioning and secure mounting using adhesive, either through viewing the aperture or alignment features, and adjusting the light sensor's position based on detected light intensity or reflection for optimal alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If light sensors are mounted within a device enclosure and transmit and receive light through a transparent aperture, then the sensors can be protected and integrated into the device structure, but misalignment with the aperture occurs leading to diminished signal strength
Solution Approach 1:
The patent applies preliminary action by providing alignment features (such as alignment marks or alignment structures) on the sensor assembly that can be detected by imaging equipment during assembly. This allows the sensor assembly to be pre-aligned with the aperture before final mounting, ensuring optimal signal strength while maintaining the protective enclosure structure.
2Manufacturing precision
If alignment features are added to light sensors to facilitate alignment, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The patent applies local quality by adding alignment features only at specific locations on the sensor assembly (such as alignment marks on the housing or alignment structures near the sensor), rather than modifying the entire sensor structure. This provides the necessary alignment precision while minimizing the increase in overall device complexity.
3Manufacturing precision
If automated alignment systems with cameras and actuators are used, then alignment precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies mechanics substitution by replacing complex mechanical alignment systems with an optical detection approach. Imaging equipment (cameras) captures images of the alignment features, and computational algorithms determine the precise alignment, substituting mechanical measurement and adjustment mechanisms with optical and computational methods.
4Device complexity
If manual alignment methods are used, then device complexity is reduced, but alignment precision and signal strength deteriorate
Solution Approach 1:
The patent applies self-service by designing alignment features that can be automatically detected by imaging equipment during the assembly process. The system uses images of these features to autonomously determine the correct alignment position, enabling automated precision alignment without requiring complex external alignment apparatus or skilled manual 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
This method ensures accurate alignment of light sensors with apertures, enhancing signal strength and performance by securely attaching the sensors to the device enclosure, thereby improving the functionality of proximity and ambient light sensors.
Implementation Method 1
a camera may be used to view the aperture through a mounting structure for the light sensor
Implementation Method 2
a light-generating element on a proximity sensor may be used to emit light through the aperture and onto a camera
Implementation Method 3
a light-generating element on a proximity sensor may be used to emit light through the aperture that is reflected from an object back through the aperture onto a light sensitive portion of the proximity sensor
Implementation Method 4
adhesive may be used to secure the support structure to the transparent cover layer
Data Source
AI summary
Electronic devices may include light sensors. The light sensors may include alignment features. The light sensors may be optically aligned with an aperture in an opaque structure. The opaque structure may be formed from an opaque material or a transparent material with an opaque coating. The light sensor may be mounted in a support structure that has been optically aligned with the aperture. The light sensor or the support structure may include extended portions that are transparent to ultraviolet light. Ultraviolet light may be transmitted through the extended portions to cure adhesive that attaches the light sensor or the support structure to the opaque structure. The light sensor may be optically aligned with the aperture by viewing the aperture through an opening in the support structure, by viewing the alignment features on the light sensor through the aperture or by gathering alignment data using the light sensor during alignment operations.