Optical Coupler Integrated Lead Frame Casing Assembly
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Solution Overview
Problem
Conventional optical couplers have a high parts count and complex assembly processes, leading to issues like electrical shorts and inventory management challenges due to varying connector pitches and the need for welding or soldering.
Innovation Solution
An optical coupler design with a reduced parts count, featuring a lead frame integrated into a light-shielding resin exterior casing that can be divided into two sections for easy assembly without welding or soldering, and a manufacturing method that allows for varying connector pitches and orientations by adjusting the cutting positions on the lead frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional optical couplers use separate connector, lead frame, and exterior casing components, then connection reliability is improved, but assembly complexity and parts count increase
Solution Approach 1:
The patent combines the exterior casing and connector housing into a single integrated component. The connector housing is formed as an integral part of the exterior casing, eliminating the need for separate connector components and reducing assembly steps while maintaining connection reliability through the integrated design.
Solution Approach 2:
The integrated exterior casing serves multiple functions simultaneously: it provides mechanical protection for the optical components, houses the connector, and structures the overall device. This multi-functional design reduces parts count while maintaining the protective and connective functions of separate components.
2Strength
If welding or soldering steps are used to connect connectors to lead frames, then connection strength is improved, but manufacturing complexity and time increase
Solution Approach 1:
The connector and exterior casing are designed as an integrated unit, eliminating the need for welding or soldering steps. The connector terminals are directly formed as part of the casing structure, allowing for simpler assembly processes while maintaining connection strength through the integral design.
Solution Approach 2:
The patent replaces thermal joining methods (welding, soldering) with mechanical integration. The connector is structurally incorporated into the casing through molded or formed integral connections, substituting complex thermal processes with simpler mechanical formation processes.
3Adaptability or versatility
If multiple types of lead frames are used to accommodate different connector pitches, then adaptability is improved, but inventory management complexity increases
Solution Approach 1:
The lead frame is designed with flexible terminal positioning capability, allowing the same lead frame structure to accommodate different connector pitches by adjusting terminal locations. This dynamic adaptability eliminates the need for multiple fixed-pitch lead frame variants, simplifying inventory management while maintaining versatility.
Solution Approach 2:
A single lead frame design serves multiple connector pitch requirements through configurable terminal arrangements. The universal lead frame structure can be adapted to different pitch specifications without requiring separate lead frame types, reducing inventory complexity while maintaining adaptability to various connector standards.
Data Source
AI summary
A device unit 46 is constituted by including a lead frame 50 on which a light-emitting mold portion 48 and a light-receiving mold portion 49 are mounted. Moreover, an exterior casing for housing the device unit 46 is constituted of two parts dividable into an upper casing 45 and a lower casing 47. Thus, by holding the device unit 46 by the upper casing 45 and the lower casing 47, external connection terminals 43 constructed of one end portion of the lead frame 50 can be fixed to the exterior casing and positioned in a connector portion 42. Therefore, by reducing the parts count to three and allowing the device unit 46 to be fixed to the exterior casing by a fixed fitting mechanism of the upper casing 45 and the lower casing 47 without performing welding, soldering, thermal caulking or the like, the assembling becomes easy.