Optical Housing Flex Substrate Layout for Easier Terminal Bonding
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Solution Overview
Problem
Existing optical apparatuses with flexible substrates housed in a housing face issues such as difficulty in bending and terminal misalignment, leading to challenges in connecting conductive wires and components.
Innovation Solution
The optical apparatus features a flexible substrate with conductive wires covered by an insulation layer and arm parts protruding from a base part, allowing for easier bending and connection to external conductors, with various connection structures enhancing conductivity and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulation layer is interposed between two conductive wires adjacent to each other over almost the entire section of the conductive wires, then the insulation between conductive wires is improved, but the flexibility of the substrate deteriorates and connection becomes difficult
Solution Approach 1:
The substrate is divided into a base part and multiple arm parts. The arm parts can be bent independently to facilitate connection operations, while the base part maintains the insulation structure. This segmentation allows the conductive wires in arm parts to be connected without the constraint of continuous insulation coverage, resolving the contradiction between insulation reliability and connection ease.
Solution Approach 2:
The insulation layer is selectively applied only in the base part where conductive wires require insulation, while the arm parts have reduced or no insulation coverage to enable flexibility and easier connection. This local differentiation of insulation quality allows the system to maintain reliable insulation where needed while achieving flexibility where connection operations are required.
2Reliability
If the flexible substrate is made rigid to maintain insulation layer integrity, then insulation reliability is improved, but the ability to bend and adapt to positioning shifts deteriorates
Solution Approach 1:
The substrate structure is segmented into a rigid base part that maintains insulation layer integrity and flexible arm parts that can bend and adapt to positioning shifts. This segmentation allows the base part to provide stable insulation while the arm parts provide the necessary adaptability for connection operations.
Solution Approach 2:
The arm parts are designed to be dynamically flexible, allowing them to bend and adjust their positions to accommodate shifts in component terminal positions. This dynamic capability enables the substrate to adapt to positioning variations while the base part maintains structural stability and insulation integrity.
3Reliability
If the insulation layer covers the entire conductive wire, then insulation reliability is improved, but the ease of bonding and connection deteriorates
Solution Approach 1:
The substrate is segmented such that the base part has complete insulation coverage for reliable insulation, while the arm parts have reduced insulation coverage to expose conductive wire surfaces. This segmentation facilitates easier bonding operations in the arm parts where connection operations are performed, while maintaining insulation reliability in the base part.
Solution Approach 2:
The insulation layer is applied with different coverage quality in different regions: complete coverage in the base part for insulation reliability, and reduced or selective coverage in the arm parts to expose conductive surfaces for easier bonding and connection operations.
Data Source
AI summary
An optical apparatus includes: a housing; at least one component housed in the housing, the at least one component being configured to be energized and perform at least one of outputting light, receiving light, and changing a property of light; a plurality of external connection conductors configured to penetrate through the housing; and a flexible substrate housed in the housing, the flexible substrate including an insulation layer, a plurality of conductive wires each configured to perform at least one of conduction between the component and the external connection conductors, conduction between the external connection conductors, and conduction between a plurality of the components each serving as the at least one component, a base part in which the conductive wires are covered by the insulation layer, and a plurality of arm parts protruding and extending from the base part, each including one of the conductive wires.