Integrated Optical Scale Sensing Chip Structure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Optical scale readers in the precision engineering industry face challenges with equipment miniaturization due to the bulky structure of vernier scales and interference from air, dust, and particles in the separation space between the vernier scale and photosensitive module, affecting measurement accuracy.
Innovation Solution
A sensing chip structure integrating a photosensitive chip with a grating pattern layer, eliminating the need for a separate vernier scale and reducing space requirements, while using a light-penetrable insulating layer and transparent protective layer made of polyimide epoxy resin to protect the grating pattern and pins, ensuring precise light interaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a separate vernier scale and photosensitive module are used with a separation space, then the photosensitive module can detect light intensity changes, but the optical scale reader takes up too much space
Solution Approach 1:
The vernier scale grating pattern is directly formed on the photosensitive chip substrate, merging two previously separate components (vernier scale and photosensitive module) into a single integrated sensing chip. This eliminates the separation space and connecting elements, achieving miniaturization while maintaining detection capability
Solution Approach 2:
The photosensitive chip serves multiple functions: it acts as both the photosensitive module for detecting light intensity changes and as the substrate for the vernier scale grating pattern. This multi-functionality reduces the number of separate components needed
2Ease of manufacture
If a separation space is maintained between vernier scale and photosensitive module, then assembly is simplified, but air, dust and suspended particles cause refraction and diffraction of light rays
Solution Approach 1:
By integrating the vernier scale grating pattern directly onto the photosensitive chip substrate, the invention eliminates the separation space that previously allowed contamination. The grating pattern is formed on the substrate surface, creating a compact structure where the light path is direct and uncontaminated
Solution Approach 2:
The substrate itself acts as a thin film or layer that supports the grating pattern while maintaining close proximity to the photosensitive elements. This thin-film approach eliminates the need for a bulky separation space while preserving the optical path
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 enables miniaturization of optical scale readers, enhancing measurement precision by eliminating interference from air, dust, and particles, and providing accurate displacement measurements.
Implementation Method 1
The aforesaid relative displacement causes continuous changes in light intensity, which are sensed by the photosensitive module 72 and converted into displacement-related distances
Implementation Method 2
an insulating layer which is light-penetrable and covers the coded graphic layer
Data Source
AI summary
A sensing chip structure of an optical scale reader includes a substrate having at least one conductive pad. The substrate has thereon a photosensitive chip. The photosensitive chip has at least one pin. The pins are each connected to a conductive pad by a conducting wire. A coded graphic layer is disposed on a side of the photosensitive chip, and the side of the photosensitive chip faces away from the substrate. The sensing chip structure is conducive to structural simplification and miniaturization of the optical scale reader.