Optical Encoder Module Dual Resin Bonding Stability
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Solution Overview
Problem
Existing optical encoders face challenges in achieving high detection accuracy and stable disposition of the fiber optical plate on the light receiving element, requiring a design that meets specific performance requirements.
Innovation Solution
The optical module for an encoder incorporates a first resin member with high light transmittance to bond the fiber optical plate to the light receiving element and a second resin member with lower light transmittance and higher hardness to support the assembly, allowing for improved stability and noise light blocking, while using different materials for each resin member to enhance design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single resin member is used to bond and support the fiber optical plate, then the structure is simple, but the detection accuracy and stability cannot be optimized
Solution Approach 1:
The resin member is divided into two distinct parts: a first resin member for bonding the fiber optical plate to the light receiving element, and a second resin member for supporting the fiber optical plate on the bottom wall part. This segmentation allows each resin member to be optimized for its specific function, improving detection accuracy while maintaining structural clarity.
Solution Approach 2:
Different regions of the resin member structure are assigned different material properties. The first resin member uses a material optimized for bonding performance and light transmittance, while the second resin member uses a material optimized for mechanical support and stability. This local quality differentiation resolves the contradiction between precision and complexity.
2Use of energy by moving object
If the resin member has high light transmittance to allow light passage, then light transmission is efficient, but noise light from external sources cannot be blocked
Solution Approach 1:
The patent applies different light transmittance properties to different parts of the resin member structure. The first resin member in contact with the light receiving element uses high light transmittance material to ensure efficient signal light transmission, while the second resin member uses low light transmittance material to block external noise light. This local differentiation resolves the contradiction between light transmission efficiency and noise blocking.
3Stability of the object's composition
If the resin member is soft to suppress peeling, then bonding stability is improved, but mechanical support and positioning precision deteriorate
Solution Approach 1:
The resin member is segmented into two functional parts with different hardness properties. The first resin member uses a soft material to prevent peeling between the fiber optical plate and light receiving element, while the second resin member uses a hard material to provide precise mechanical support and positioning. This segmentation resolves the contradiction between bonding stability and positioning precision.
Solution Approach 2:
Different hardness characteristics are assigned to different locations in the resin member structure based on functional requirements. The bonding interface requires softness for stability, while the support structure requires hardness for precision. This local quality differentiation enables both requirements to be satisfied simultaneously.
4Reliability
If the fiber optical plate is firmly bonded to achieve stable disposition, then detection reliability improves, but the design flexibility for optimizing performance is reduced
Solution Approach 1:
The patent employs different material properties in different parts of the resin member structure to simultaneously achieve firm bonding and design flexibility. The first resin member uses materials optimized for bonding strength and light transmittance, while the second resin member uses materials optimized for mechanical support. This local quality approach allows the design to be tailored to specific performance requirements while maintaining reliable bonding.
Solution Approach 2:
The resin member structure uses composite material selection, combining different resin materials with complementary properties. This allows the system to achieve both firm bonding for reliability and design flexibility for optimizing detection performance, as each material can be selected independently based on its specific function.
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 configuration enhances detection accuracy by blocking noise light and stabilizes the fiber optical plate's position, reducing the risk of peeling, and improves manufacturing efficiency by allowing for precise bonding and reduced resin member overlap.
Implementation Method 1
a first resin member disposed between the light receiving surface and the output surface and bonding the fiber optical plate to the light receiving element
Implementation Method 2
a second resin member disposed on a surface of the bottom wall part so as to be in contact with the light receiving element and the fiber optical plate
Implementation Method 3
a fiber optical plate including an input surface constituted by surfaces of one end of a plurality of optical fibers and an output surface constituted by surfaces of the other end of the plurality of optical fibers
Implementation Method 4
a light receiving element including a light receiving surface and disposed on a surface of the bottom wall part with the light receiving surface facing a side opposite to the bottom wall part
Data Source
AI summary
An optical module includes: a support having a bottom wall part; a light receiving element disposed on a surface of the bottom wall part with a light receiving surface facing a side opposite to the bottom wall part; an FOP having an input surface and an output surface and disposed on the light receiving element with the output surface facing the light receiving surface; a first resin member disposed between the light receiving surface and the output surface and bonding the FOP to the light receiving element; and a second resin member disposed on the surface of the bottom wall part so as to be in contact with the light receiving element and the FOP. A material for the first resin member and a material for the second resin member are different from each other.