Optical Module Halbach Magnet Assembly Without Adhesive Bonding
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Solution Overview
Problem
The existing methods for bonding magnets in a Halbach array for optical modules are unreliable and costly, as they rely on adhesive resins that can lead to separation of magnets and increase workload and costs.
Innovation Solution
An optical module design featuring a magnet portion with a Halbach structure, where a first magnet and a pair of second magnets are supported by a package with a bottom wall, side wall, and restriction portion, preventing relative movement and eliminating the need for adhesive resins, thereby enhancing reliability and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive resin is used to bond multiple magnets in a Halbach array, then the magnets can be assembled, but the workload and manufacturing costs increase
Solution Approach 1:
The patent combines the magnet assembly function with the package structure. The side walls and bottom wall of the package are designed to simultaneously hold multiple magnets in their correct positions, eliminating the need for separate adhesive bonding steps. This integration reduces manufacturing complexity and improves productivity.
2Ease of manufacture
If adhesive resin is used to bond magnets, then magnets can be fixed together, but additional materials and processing steps are required, increasing costs
Solution Approach 1:
The invention extracts and removes the adhesive resin from the magnet fixation system. By using the package structure's side walls and bottom wall to mechanically constrain the magnets, the patent eliminates the need for adhesive materials and the associated bonding process steps, thereby reducing device complexity and manufacturing costs.
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
The optical module achieves improved reliability by preventing magnet separation and reducing costs by avoiding the use of adhesive resins, while efficiently utilizing the magnetic field for the movable mirror portion.
Implementation Method 1
a magnet portion (50) having an upper surface (50a), a bottom surface (50b), and a side surface (50s) extending from the upper surface to the bottom surface, and configured to generate a magnetic field acting on the movable mirror portion
Implementation Method 2
a first magnet (51) including a first area (51b) of the bottom surface and applied with a force in a first direction (D1) from the upper surface to the bottom surface, and a pair of second magnets (52, 53)
Data Source
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AI summary
An optical module includes a mirror unit having a movable mirror portion, a magnet portion configured to generate a magnetic field acting on the movable mirror portion, and a package accommodating the magnet portion. The magnet portion has a Halbach structure including a first magnet applied with a force in a first direction, and a second magnet applied with a force in a second direction. The package has a bottom walls portion, a side wall portion, and a restriction portion configured to restrict movement of the second magnet in the second direction. The movable mirror portion is disposed in a space formed by the restriction portion.