Optical Module Magnet Unit Recess Design for Mirror Alignment
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Solution Overview
Problem
The integration of magnets in optical modules can lead to positional deviations and step formations, causing inclination deviations in mirror devices, which affect the reliability of the optical module.
Innovation Solution
An optical module design that includes a mirror unit with a movable mirror portion and a magnet unit with a recessed package configuration, where the magnet unit is fixed to the base wall portion and the mirror unit is positioned on the opposite side, allowing for accurate alignment and preventing contact between the magnet unit's bottom surface and the package, thereby minimizing inclination deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the magnet unit is formed by integrating three magnets through bonding, then the magnetic field generation is achieved, but the position of the magnet unit deviates in the up-down direction and step portions are formed on the upper and bottom surfaces
Solution Approach 1:
The magnet unit is divided into three separate magnets arranged along the lateral direction with different magnetic directions. This segmentation allows each magnet to be independently positioned and bonded, reducing cumulative positioning errors and preventing the formation of step portions on the surfaces.
Solution Approach 2:
Each magnet in the magnet unit is given a specific local magnetic direction (different from each other) to optimize the magnetic field distribution. This local quality differentiation enables precise control of the magnetic field while maintaining surface flatness through careful arrangement.
2Ease of manufacture
If the mirror device is disposed on the upper surface of the magnet unit with step portions, then the mirror device can be mounted, but the inclination of the mirror device deviates from the target angle
Solution Approach 1:
The magnet unit is designed with a flat upper surface before the mirror device is mounted. By eliminating step portions in advance through proper magnet arrangement and bonding, the mirror device can be mounted at the correct target angle without subsequent adjustment needs.
3Stability of the object's composition
If the magnet unit is embedded in the package by insert molding, then the structure is integrated, but unevenness occurs on the package surface due to step portions causing inclination deviation
Solution Approach 1:
The magnet unit consists of three separately arranged magnets with different magnetic directions, which when bonded together form a unified structure with a flat upper and bottom surface. This segmented approach to creating the magnet unit prevents step portions that would otherwise cause surface unevenness during insert molding.
4Stability of the object's composition
If the bottom surface of the magnet unit contacts the package, then the structure is stable, but the step portions on the bottom surface cause inclination deviation
Solution Approach 1:
The magnet unit is designed with a flat bottom surface before assembly, eliminating step portions in advance. This preliminary action ensures that when the magnet unit is assembled and the bottom surface contacts the package, the contact is uniform without causing inclination deviations in the mirror device.
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 enhances the reliability of the optical module by preventing inclination deviations due to step formations and ensures accurate positioning, reducing the risk of damage to the magnet unit and improving the module's overall performance.
Implementation Method 1
a magnet unit having an upper surface, a bottom surface, and a side surface extending from the upper surface to the bottom surface, and generating a magnetic field acting on the movable mirror portion
Data Source
AI summary
An optical module includes a mirror unit, a magnet unit, and a package including a recess accommodating the magnet unit. The magnet unit includes a plurality of magnets arranged along a first direction. The recess includes a base wall portion which extends along the first direction and to which an upper surface of the magnet unit is fixed, and a side wall portion extending along a second direction intersecting the first direction, and facing a side surface of the magnet unit. The recess includes an opening portion that is delimited by the side wall portion and open to a lower side. The mirror unit is disposed on a second surface on an opposite side of the base wall portion from a first surface to which the magnet unit is fixed. The side wall portion protrudes to the lower side with respect to a bottom surface of the magnet unit.