Optical Module Housing Matrix for Compact, Reduced-Damage Handling
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Solution Overview
Problem
Existing optical modules, such as proximity sensors, 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 includes a housing with a singulation portion on its outer sidewall, formed by cutting a housing matrix module, which allows for reduced wall thickness and improved handling efficiency, and a method of manufacturing involving a housing matrix module that is singulated and assembled onto a carrier with optical elements, enabling precise placement and reduced damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the housing wall thickness is reduced to minimize module size, then the optical module size is reduced, but the housing becomes more fragile and prone to damage during handling and inspection
Solution Approach 1:
The housing is divided into multiple individual units from a housing matrix module, with singulation portions creating defined separation zones. This segmentation allows each housing to be optimized for minimal thickness while the matrix structure provides structural support during manufacturing and handling, reducing overall damage risk.
2Manufacturing precision
If multiple housings are manufactured separately to ensure quality control, then manufacturing precision is improved, but manufacturing efficiency and productivity decrease
Solution Approach 1:
Multiple housings are combined into a single housing matrix module for manufacturing. The matrix structure allows simultaneous production of multiple housings with consistent quality control, while the singulation portions enable easy separation into individual units. This merging approach improves manufacturing efficiency without sacrificing precision.
Solution Approach 2:
The housing matrix module is pre-manufactured as a complete unit with all housings formed simultaneously. This preliminary action ensures consistent quality across all housings before they are separated into individual units, maintaining manufacturing precision while improving overall productivity.
3Strength
If the housing is designed as a single integrated piece to maintain structural integrity, then housing strength is improved, but the optical module size increases and handling efficiency decreases
Solution Approach 1:
The housing is segmented into multiple individual units within a matrix structure. Each individual housing can be minimized in size, while the overall matrix structure provides structural integrity during manufacturing and handling. The singulation portions create defined separation zones that maintain structural strength.
4Measurement precision
If housings are handled individually during assembly and inspection, then inspection precision is improved, but handling time and damage risk increase
Solution Approach 1:
Multiple housings are combined in a matrix structure for assembly and inspection processes. This allows simultaneous handling of multiple units, reducing overall handling time while the singulation portions enable easy separation for individual inspection when needed, maintaining inspection precision without excessive time loss.
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.