Optical Module Housing Singulation for Compact Assembly
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Solution Overview
Problem
Existing optical modules face challenges in reducing size, improving manufacturing efficiency, and minimizing damage during handling and inspection, while maintaining cost-effectiveness.
Innovation Solution
The optical module design incorporates a housing with a singulation portion on its outer sidewall, formed by cutting a housing matrix module, which allows for reduced wall thickness and efficient assembly, enabling smaller size and improved handling, inspection, and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the housing wall thickness is reduced to achieve smaller optical module size, then the device size is reduced, but the structural strength and reliability deteriorate
Solution Approach 1:
The housing is segmented into multiple portions (first portion, second portion, third portion) with different wall thicknesses. The first portion has reduced wall thickness to minimize overall device size, while the second and third portions maintain adequate wall thickness for structural strength. This segmentation allows the housing to simultaneously achieve compact dimensions and sufficient mechanical integrity.
2Productivity
If traditional housing manufacturing methods are used, then manufacturing process is simple, but manufacturing efficiency is low and damage during handling occurs
Solution Approach 1:
Multiple housings are manufactured together as a single integrated housing matrix module, which is then singulated into individual housings. This merging approach enables batch processing, improving manufacturing efficiency and reducing handling damage compared to producing individual housings separately. The singulation process creates defined separation portions that facilitate clean separation of individual units.
3Ease of operation
If the housing is designed as a single integrated structure, then structural strength is maintained, but handling and inspection quality are compromised
Solution Approach 1:
The housing is divided into distinct portions (first, second, third portions) with defined boundaries. The first portion can be handled and inspected separately from the second and third portions, improving ease of operation during manufacturing and quality control. The segmentation is designed such that each portion maintains adequate structural integrity for its specific function while the complete assembly provides overall structural strength.
Data Source
AI summary
An optical module includes: a carrier; an optical element disposed on the upper side of the carrier; and a housing disposed on the upper side of the carrier, the housing defining an aperture exposing at least a portion of the optical element, an outer sidewall of the housing including at least one singulation portion disposed on the upper side of the carrier, wherein the singulation portion of the housing is a first portion of the housing, and wherein the housing further includes a second portion and a surface of the singulation portion of the housing is rougher than a surface of the second portion of the housing.