Optical Module Diffuser BCC Lattice Support
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Solution Overview
Problem
Optical modules, such as ambient light sensors, face a challenge in achieving a greater detection angle and uniform light distribution while maintaining miniaturization, as existing structures that enhance these aspects often increase the size of the module.
Innovation Solution
The optical module design includes a carrier, electronic components, a lid, a diffuser, and a bonding layer, where the diffuser is positioned within an aperture defined by the lid, and a bonding layer with a BCC lattice structure is used between the diffuser and the aperture's sidewall to support the diffuser and enhance light uniformity without increasing the module's thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a structure with greater detection angle and uniform light distribution is implemented, then light detection performance is improved, but the size of the optical module increases
Solution Approach 1:
The diffuser is positioned within the aperture of the lid, nesting the light diffusion function inside the existing module structure. This allows the diffuser to be integrated into the aperture space rather than adding external components, improving light uniformity while maintaining compact dimensions.
Solution Approach 2:
The patent introduces a bonding layer with BCC lattice structure that extends in the vertical dimension (thickness direction) to support the diffuser. This vertical dimensionality change allows the diffuser to be properly supported and positioned without increasing the horizontal footprint of the module, thus maintaining miniaturization while achieving uniform light distribution.
2Illumination intensity
If the diffuser is supported by a bonding layer with BCC lattice structure, then light uniformity is improved, but the manufacturing complexity increases
Solution Approach 1:
The bonding layer uses a specific BCC (body-centered cubic) lattice structure with controlled thickness and material properties. By changing the crystal structure parameter to BCC and optimizing the thickness to be greater than the aperture depth, the layer provides sufficient mechanical support for the diffuser while maintaining optical performance. This parameter optimization achieves light uniformity without requiring overly complex manufacturing processes.
3Volume of moving object
If the aperture depth is reduced to maintain miniaturization, then module thickness is reduced, but the diffuser support becomes insufficient
Solution Approach 1:
The bonding layer's support capability is enhanced by extending its thickness in the vertical dimension beyond the aperture depth. This dimensional extension provides sufficient mechanical support for the diffuser even when the aperture itself is shallow, allowing the module to maintain miniaturized thickness while ensuring adequate diffuser support through the bonding layer's extended vertical presence.
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 design improves light uniformity and detection angle without enlarging the optical module, allowing for better performance in electronic devices while maintaining miniaturization.
Implementation Method 1
The diffuser is disposed within the first aperture... This design improves light uniformity and detection angle
Implementation Method 2
The bonding layer includes a material crystalized in BCC lattice
Data Source
AI summary
An optical module and a method of manufacturing an optical module are provided. The optical module includes a carrier, an electronic component, a lid, a diffuser and a bonding layer. The electronic component is disposed on the carrier. The lid is disposed on the carrier. The lid has a first cavity to accommodate the electronic component. The lid defines a first aperture over the first cavity. The diffuser is disposed within the first aperture. The bonding layer is disposed between the diffuser and a sidewall of the first aperture.