Optical Module Snap-Fit Housing Alignment
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Solution Overview
Problem
Lateral flow test readers with integrated light sources and detectors suffer from positional misalignment due to reflow issues during manufacturing, leading to inaccurate and unreliable quantitative measurements.
Innovation Solution
An optical module with imaging components integrated on a substrate and aligned with a housing that has shaped surfaces or legs to secure positional alignment, minimizing movement and misalignment during reflow, ensuring consistent and reproducible results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If discrete optical components (LEDs, photodiodes) are assembled on a printed circuit board using pick and place machines with glue and solder, then the device can be manufactured with standard assembly processes, but positional misalignment occurs due to reflow at high temperatures during manufacturing steps
Solution Approach 1:
The patent merges the optical components (light source, optical detector) and their support structure (substrate, housing) into a single integrated optical module assembly. This integration ensures that all components move together as one unit during reflow, eliminating relative positional misalignment between components while maintaining compatibility with standard pick and place assembly processes.
Solution Approach 2:
The patent introduces a substrate as an intermediary platform that mechanically couples the light source and optical detector together. This substrate acts as a stable reference frame that prevents relative movement between components during thermal reflow, while still allowing the entire assembly to be mounted on the printed circuit board using conventional assembly methods.
2Manufacturing precision
If the housing is secured to the substrate without support to minimise reflow induced movement, then reflow misalignment is reduced, but the housing is heavier and more susceptible to reflow misalignment
Solution Approach 1:
The patent applies local quality by providing selective support structures (legs or shaped surfaces) at specific locations on the housing that interface with the substrate. These localized support points provide mechanical stability during reflow without requiring the entire housing to be heavily reinforced, thus minimizing weight while maintaining positional alignment precision.
3Measurement precision
If quantitative measurements are performed using imaging technology from an external reader device, then increased sensitivity and quantification level are achieved, but the distance between the colour change and detector is large (greater than 5-10cm) resulting in decreased signal strength
Solution Approach 1:
The patent merges the light source and optical detector into an integrated module that can be positioned much closer to the assay test region than external reader devices. This integration enables quantitative measurements with high signal strength by reducing the detection distance to minimal levels while maintaining the imaging technology capability for sensitive quantification.
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
The solution provides a miniaturized, pre-calibrated optical module with improved accuracy and reliability for lateral flow test readings, suitable for mass production and reducing manufacturing variability.
Implementation Method 1
a first light source (101) for illuminating a test region of an assay
Implementation Method 2
an optical detector (103) comprising an optical input for receiving light emitted from the test region
Data Source
Figure 1a~1b
Figure 1c~1e
Figure 1f
AI summary
An optical module (100) for reading a test region of an assay. The optical module comprises: a first light source (101) for illuminating the test region of the assay; an optical detector (103), comprising an optical input for receiving light emitted from the test region and an electrical output; a substrate (104) for mounting the first light source (101) and the optical detector (103); and a housing (105) comprising: a first opening (106) for providing a first optical path from the first light source (101) to the test region (103); wherein the housing (105) and the substrate (104) enclose and positionally align the first source (101) and the optical detector (103) relative to the first opening (106). The housing (105) may comprise one or more legs (108), such as a flexible hook portion which secures the housing (105) to the substrate (104) with a snap-fit engagement, extending from a first and/or second outer surface of the housing (105) in a vertical direction. Beneficially, the snap-fit engagement provided by the flexible hook portion allows the housing to be aligned and secured without the need to use glue or for example a screw and thread that can be difficult to control and/or risks misalignment of the housing.