Optical Module Retainer Brackets for Adjustable Lens Spacing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing optical modules are inflexible in terms of lens spacing, requiring different modules for varying spacings at the transmission and reception sides, which complicates assembly and reduces positional accuracy, leading to suboptimal performance and increased manufacturing costs.

Innovation Solution

The optical module employs retainer brackets with multiple support elements at different heights, allowing for precise adjustment of the beam-forming element's spacing relative to the carrier, enabling the same module to be used at different spacings and providing a secure, cost-effective connection resistant to vibrations and shocks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If different optical modules are used for different lens spacings, then the required spacing variations can be achieved, but the device complexity and manufacturing costs increase

Engineering Contradiction:

Improvelens spacing accuracyVSAvoidmodule variety

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The optical module is designed with a universal retainer bracket that can accommodate multiple lens spacings through adjustable support elements. The bracket includes first and second support elements positioned at different heights, allowing the same module to be used for both transmission and reception sides with different spacing requirements, thereby eliminating the need for separate optical modules for each spacing configuration

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The retainer bracket incorporates adjustable support elements that can be selectively positioned or engaged to change the lens spacing dynamically. This allows the optical module to adapt to different spacing requirements without requiring physically different modules, resolving the contradiction between maintaining precise spacing control and reducing device complexity

Inventive Principle:

Principle #15Dynamics

2Reliability

If the optical module is securely fastened to the carrier, then connection reliability improves, but positioning accuracy may be compromised

Engineering Contradiction:

Improveconnection stabilityVSAvoidpositioning accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The fastening system is segmented into multiple independent retainer brackets, each with its own support elements. This segmentation allows each bracket to independently secure the optical module while maintaining precise positioning, as each segment can be optimized for both holding force and alignment without compromising the other

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The retainer bracket acts as an intermediary element between the optical module and the carrier board. It provides a standardized interface that ensures both secure mechanical attachment and accurate positioning, mediating between the requirements for strong connection and precise alignment without direct attachment of the optical module to the carrier

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If traditional fastening methods like screwing or adhesively bonding are used, then connection strength is achieved, but manufacturing effort and cost increase

Engineering Contradiction:

Improveconnection strengthVSAvoidassembly complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The complex mechanical fastening systems (screws, adhesives) are replaced with a simplified mechanical retention system using retainer brackets with support elements. This substitution maintains connection strength through precise mechanical engagement while dramatically reducing assembly complexity and manufacturing cost by eliminating the need for threading operations, adhesive application, or curing processes

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution allows for high-accuracy positioning of the optical module at various spacings, enhancing the range and reliability of the system while simplifying assembly and reducing manufacturing costs, with improved beam alignment and increased resistance to environmental influences.

Implementation Method 1

The optical module frequently includes a lens tube besides the lens

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 2

the beam-forming element, frequently configured as a lens

Methodology Applied

Scientific EffectLens focusing: Lens

Data Source

PatentUS9791658B2Optical module and method for producing an optoelectronic sensor

Publication Date: 2017.10.17 SICK AG

AI summary

An optical module (10) having at least one beam-forming element (14) and having at least two retainer brackets (20) for fastening the optical module (10) to a carrier (30) are provided. In this connection the retainer brackets (20) have a first support element (22a) at a first spacing with respect to the lens (14) and a second support element (22b) at a second spacing different from the first spacing with respect to the beam-forming element (14) in order to selectively fasten the optical module (10) to the carrier (30) at the first spacing or at the second spacing.