Optical Module Sealing Structure to Prevent Resin-Induced Misalignment
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Solution Overview
Problem
Existing optical modules suffer from deformation due to resin expansion, leading to misalignment of optical components and deterioration of optical characteristics, particularly when exposed to moisture.
Innovation Solution
The optical module design features a housing with specific sidewall and cover member configurations, where the resin is only applied on one side, allowing it to deform without affecting the housing, and using ultraviolet curable resin for efficient sealing and positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin is applied between the cover member and housing to seal and fix them, then sealing and fixation are improved, but housing deformation occurs due to resin expansion when exposed to moisture
Solution Approach 1:
The resin application area is segmented into specific regions: the resin is applied only to the first sidewall's outer surface, not to all sidewalls. This selective segmentation allows the resin to provide sealing where needed while avoiding expansion-induced deformation on other critical surfaces, thus resolving the contradiction between sealing performance and housing stability.
Solution Approach 2:
Different regions of the housing are treated with different qualities: the first sidewall receives resin application for sealing, while other sidewalls remain resin-free to maintain structural stability. This local differentiation of quality allows the system to achieve both sealing performance and resistance to deformation by applying the resin only where it is most beneficial.
2Strength
If resin is applied to seal the gap between housing and cover member, then fixation strength is improved, but optical component alignment deteriorates due to housing deformation
Solution Approach 1:
The resin application is segmented to specific sidewalls only, providing sufficient fixation strength at the sealed interfaces while avoiding resin-induced deformation that would compromise optical component alignment. This selective application maintains both fixation strength and manufacturing precision.
Solution Approach 2:
The housing structure exhibits local quality differentiation where resin is applied to certain sidewalls for fixation purposes while other sidewalls remain free of resin to maintain dimensional stability for optical alignment. This local quality approach ensures both strong fixation and precise optical component positioning.
3Reliability
If resin is applied on all sidewalls for complete sealing, then sealing performance is improved, but device complexity increases due to manufacturing difficulties
Solution Approach 1:
The sealing structure is segmented such that resin is applied only to specific sidewalls rather than all sidewalls. This segmentation reduces manufacturing complexity by limiting resin application areas while still achieving effective sealing performance through strategic placement of the sealing material on critical interfaces.
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 prevents housing deformation and maintains optical component alignment, ensuring stable optical characteristics by allowing resin to expand or shrink without influencing the module's structure, thereby enhancing the module's moisture resistance and manufacturing efficiency.
Implementation Method 1
An ultraviolet curable resin may be used for the resin
Implementation Method 2
When the resin 930 expands due to moisture absorption, the resin 930 deforms so that the housing 910 is strongly pressed
Data Source
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AI summary
The present invention provides an optical module that can maintain optical characteristics of an optical component placed in an accommodation space. A laser module 1 has a base portion 12 on which optical components 40-42 are mounted, a housing 10 including sidewalls 31-34 extending from the base portion 12 in a height direction, a cover member 20 that defines, along with the housing 10, an accommodation space S, and a resin 70 for fixing the housing 10 and the cover member 20 to each other. The sidewall 31 includes a counter portion 61 having a lateral counter surface 61A. The sidewall 32 has a cover support surface 52 for supporting the cover member 20. The sidewall 33 includes a counter portion 63 having a lateral counter surface 63A. The sidewall 34 has a cover support surface 54 for supporting the cover member 20. The lateral counter surface 61A of the counter portion 61 and the lateral cover surface 21 of the cover member 20 are opposed to each other while the resin 70 is interposed therebetween. The lateral counter surface 63A of the counter portion 63 and the lateral cover surface 23 of the cover member 20 are opposed to each other while the resin 70 is interposed therebetween. The lateral cover surfaces 22 and 24 of the cover member 20 are exposed to an outside.