Liquid Sensor Optical Waveguide with Embedded Reflecting Plates
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Solution Overview
Problem
Existing liquid sensors are complex and costly to manufacture, with inefficiencies in light reflection and leakage that affect the accuracy of liquid state detection.
Innovation Solution
A liquid sensor design incorporating an optical waveguide with embedded metal plates that function as reflecting portions, allowing for insert molding to form the waveguide and reflecting surfaces simultaneously, reducing manufacturing complexity and cost, and enhancing light detection accuracy by minimizing leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional liquid sensor manufacturing methods are used, then manufacturing precision can be maintained, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the optical waveguide structure and reflecting portions into a single integrated component. The optical waveguide includes first and second pillar portions with embedded metal plates that serve as reflecting portions, eliminating the need for separate reflecting components and reducing assembly steps while maintaining manufacturing precision.
Solution Approach 2:
The optical waveguide structure serves multiple functions simultaneously: it guides light from the light emitting element to the light receiving element, provides structural support through its pillar portions, and incorporates reflecting portions via embedded metal plates to redirect light paths. This multi-functionality reduces the number of separate components needed.
2Measurement precision
If embedded metal plates are used as reflecting portions, then light reflection efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The metal plates are embedded directly into the optical waveguide structure during the molding process, combining the waveguide fabrication and reflecting portion creation into a single manufacturing step. This integration maintains high light reflection efficiency while avoiding the complexity of separate assembly operations.
Solution Approach 2:
The metal plates are prepared and positioned within the optical waveguide structure before the final molding process. This preliminary action ensures that the reflecting portions are correctly positioned and integrated, simplifying the overall manufacturing process while maintaining detection accuracy.
3Reliability
If side wall portions are added to metal plates, then light leakage is reduced, but manufacturing complexity increases
Solution Approach 1:
Side wall portions are added to the metal plates at specific locations where light leakage is most likely to occur. These localized structural additions provide the necessary light containment while minimizing the overall increase in structural complexity. The side wall portions extend from the metal plate surfaces to block light paths that would otherwise leak.
4Productivity
If insert molding is used to form optical waveguide and reflecting portions simultaneously, then productivity improves, but manufacturing precision requirements increase
Solution Approach 1:
The metal plates are pre-positioned and secured within the molding cavity before the optical waveguide material is injected. This preliminary positioning ensures that the reflecting portions are correctly located relative to the light emitting and receiving elements, maintaining manufacturing precision while enabling simultaneous formation of all components in a single molding 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
The design enables easier and cost-effective manufacturing of liquid sensors with improved light reflection and reduced leakage, leading to more accurate detection of liquid states.
Implementation Method 1
The first metal plate includes a first reflecting portion that is tilted relative to the first end surface and is configured to reflect the light toward the second pillar portion
Implementation Method 2
The second metal plate includes a second reflecting portion that is tilted relative to the second end surface and is configured to reflect the light from the first metal plate toward the light receiving element
Data Source
AI summary
Provided is a liquid sensor or the like that is relatively easy to manufacture. The liquid sensor includes a light emitting element, an optical waveguide, a light receiving element, and a detection circuit. The optical waveguide includes a first pillar portion, a first metal plate, a second pillar portion, and a second metal plate. The first metal plate is embedded in the first pillar portion. The second pillar portion is provided at a position opposing the first pillar portion. The second metal plate is embedded in the second pillar portion. A space for liquid is formed between the first pillar portion and the second pillar portion. The first pillar portion includes a first end surface that faces the light emitting element. The first metal plate includes a first reflecting portion that is tilted relative to the first end surface and reflects light toward the second pillar portion. The second pillar portion includes a second end surface that faces the light receiving element. The second metal plate includes a second reflecting portion that is tilted relative to the second end surface and reflects the light from the first metal plate toward the light receiving element.