Optical Assembly Layout for Adhesive-Safe Lens Alignment
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Solution Overview
Problem
In optical devices with non-hermetic containers, adhesive interference with optical paths can occur, affecting the alignment and functionality of optical elements and components.
Innovation Solution
The use of a base with convex mounting surfaces and grooves on the mounting surfaces to guide adhesive flow away from optical paths, combined with passive alignment using outer walls as markers, ensures accurate component placement and minimizes adhesive interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is used to mount optical components on a flat base surface, then components can be fixed in place, but adhesive may interfere with optical paths and affect alignment accuracy
Solution Approach 1:
The base surface is segmented into distinct functional zones: convex mounting surfaces for component attachment and grooves for adhesive containment. This segmentation prevents adhesive from spreading into optical paths while maintaining secure component fixation, thereby resolving the contradiction between reliable mounting and alignment precision.
Solution Approach 2:
Different regions of the base are given different properties: convex portions provide elevated mounting surfaces that position components above the adhesive layer, while grooves provide adhesive containment. This local differentiation ensures that adhesive remains in non-interfering positions while components maintain precise alignment, solving the contradiction between fixation reliability and alignment accuracy.
2Ease of manufacture
If a flat mounting surface is used on the base, then manufacturing is simpler, but adhesive can spread and interfere with optical paths
Solution Approach 1:
The mounting surface is divided into convex portions and grooves, creating natural boundaries that confine adhesive to specific areas. This segmentation prevents adhesive from spreading into optical paths while maintaining relatively simple manufacturing processes, thus resolving the contradiction between ease of manufacture and prevention of adhesive interference.
Solution Approach 2:
The grooves act as intermediary structures that capture and contain the adhesive, serving as a barrier between the adhesive and the optical paths. This intermediary design allows the use of adhesive for secure mounting while preventing its harmful spreading effect, resolving the contradiction between ease of manufacture and prevention of adhesive interference.
3Manufacturing precision
If outer walls are provided on the base for alignment, then component placement accuracy improves, but device structure becomes more complex
Solution Approach 1:
The outer walls of the grooves serve multiple functions: they contain adhesive within the groove areas and simultaneously provide alignment references for mounting optical components. This multi-functionality achieves high component placement accuracy without adding separate alignment structures, thereby resolving the contradiction between manufacturing precision and device complexity.
Solution Approach 2:
The groove structures perform dual roles: adhesive containment and alignment guidance. By making the alignment function inherent to the adhesive containment structure, the design avoids additional complexity while maintaining high placement accuracy, resolving the contradiction between precision and structural simplicity.
Data Source
AI summary
An optical device according to one embodiment includes: a light-emitting element; first and second lenses optically coupled with the light-emitting element; an optical component provided between the light-emitting element and the second lens, optically coupling each of the light-emitting element and the second lens, and multiplexing input lights; and a base having a lower plate having a plurality of convex mounting surfaces with each of the light-emitting element, the first lens, the second lens, and the optical component being mounted thereon and a side wall with a receptacle being connected thereto.