Optical Module Substrate Cavity Anchoring for Adhesive Strength
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Solution Overview
Problem
The existing optical modules face challenges in achieving sufficient adhesive strength between the optical coupling module and the substrate, primarily due to the limited size of the optical coupling module and the corresponding amount of adhesive applied.
Innovation Solution
Incorporating a glass cloth with protruding portions into the substrate's cavity, which increases the contact area with the adhesive, enhancing the adhesive strength by acting as an anchor, and optimizing the dimensions of the cavity and adhesive application to ensure effective bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the optical coupling module is made small to reduce size, then the overall module compactness is improved, but the adhesive strength between the optical coupling module and substrate deteriorates due to limited adhesive application area
Solution Approach 1:
The invention transitions from a two-dimensional adhesive bonding surface to a three-dimensional anchoring structure by forming protrusions that extend vertically into the adhesive layer. This dimensional change allows the adhesive to engage with the substrate through both surface area and depth, effectively increasing the bonding strength without requiring a larger optical coupling module footprint.
Solution Approach 2:
The invention changes the geometric parameters of the adhesive bonding interface by creating protrusions with specific height, width, and spacing. These parameter modifications transform the bonding mechanism from simple surface adhesion to mechanical interlocking, where the protrusions act as anchors that resist pull-off forces and enhance overall adhesive strength.
2Strength
If the adhesive application area is increased to improve bonding strength, then the adhesive strength is improved, but the optical coupling module size must be enlarged
Solution Approach 1:
Instead of expanding the adhesive application area horizontally, the invention exploits the vertical dimension by forming protrusions that extend into the adhesive layer. This allows the same footprint to provide enhanced bonding strength through increased adhesive engagement depth, effectively decoupling bonding strength from module size.
Solution Approach 2:
The invention modifies the adhesive layer parameters by creating a structured interface with protrusions of optimized height and spacing. These parameter changes enable the adhesive to achieve maximum bonding strength within a compact area, as the protrusions create multiple anchoring points that distribute and reinforce the bonding stress.
3Strength
If more adhesive is applied to increase bonding strength, then the adhesive strength is improved, but the amount of adhesive material increases and application complexity increases
Solution Approach 1:
The invention changes the adhesive application parameters by using protrusions to define precise dispensing zones. The protrusions act as physical guides that confine the adhesive to specific areas, enabling controlled application with reduced material consumption. The adhesive amount is optimized to fill the spaces between and around the protrusions, achieving maximum bonding efficiency with minimal material.
Solution Approach 2:
The protrusions serve a dual function: they provide mechanical anchoring for bonding strength enhancement and simultaneously act as application guides for the adhesive. This self-service feature eliminates the need for complex application equipment or processes, as the protrusion geometry itself directs the adhesive placement and ensures consistent bonding quality.
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 significantly improves the adhesive strength of the optical coupling module with respect to the substrate, ensuring secure optical coupling and reliable performance in optical connector cables.
Implementation Method 1
The protruding portion is stuck into the adhesive positioned between the side surface and the optical coupling module
Data Source
AI summary
An optical module includes a substrate, an optical element, an optical coupling module, and an adhesive. The substrate includes a glass cloth therein. The optical element is mounted on the substrate. The optical coupling module is configured to be optically coupled to the optical element. The adhesive fixes the optical coupling module to the substrate. A cavity recessed from a first main surface of the substrate toward a second main surface of the substrate so as to include a bottom portion is formed in the substrate. At least a part of the optical coupling module is accommodated in the cavity. The glass cloth includes a protruding portion protruding into the cavity from a side surface of the cavity. The protruding portion is stuck into the adhesive positioned between the side surface and the optical coupling module.