Optical Sensor Lens Holder Projections for Precise Adhesive Alignment
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Solution Overview
Problem
Conventional optical sensor modules face issues with adhesive agent thickness variation leading to lens misalignment and potential contact with wiring members, resulting in incorrect light reception and increased failure risk due to integrated lens holding members.
Innovation Solution
The optical sensor module features a lens holding member with projections on its bottom surface that contact the substrate, preventing adhesive agent intrusion and ensuring alignment, thereby reducing inclination and enhancing adhesion strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive agent is used to mount the lens holding member onto the substrate, then the lens holding member can be fixed to the substrate, but the adhesive agent thickness cannot be controlled, leading to lens misalignment
Solution Approach 1:
The patent applies preliminary action by pre-forming protrusions on the lens holding member before adhesion. These protrusions are designed with specific heights to pre-determine the adhesive layer thickness, ensuring that when the lens holding member is mounted onto the substrate, the adhesive thickness is automatically controlled by the protrusion height rather than varying with manual application. This preliminary structural preparation resolves the contradiction by enabling both strong adhesion and precise lens alignment.
2Strength
If the lens holding member is mounted with large adhesive agent amount or great mounting load, then the adhesive agent spreads to the inner side of the lens holding member, but this causes contact with wiring members leading to deformation or breakage
Solution Approach 1:
The patent applies segmentation by dividing the lens holding member bottom surface into multiple protrusions distributed at specific positions. This segmentation serves two functions: first, the protrusions provide localized adhesion points that achieve strong bonding without requiring large amounts of adhesive; second, they create physical barriers that contain the adhesive agent at the mounting interface, preventing it from spreading inward to contact the wiring members. This segmented structure resolves the contradiction between adhesion strength and wiring member protection.
3Ease of manufacture
If the lens holding member is inclined due to adhesive thickness variation, then the focal point of the lens deviates from the light receiving portion, but this cannot be corrected when the lens is integrated with the lens holding member
Solution Approach 1:
The patent applies preliminary action by pre-forming protrusions on the lens holding member bottom surface before the adhesion process. These protrusions are designed with precise heights to pre-determine the adhesive layer thickness, ensuring that when the lens holding member is mounted onto the substrate, the lens remains parallel to the substrate and the focal point aligns with the light receiving portion. This preliminary structural preparation eliminates the need for post-assembly correction, resolving the contradiction between integrated manufacturing simplicity and optical alignment precision.
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 design facilitates easy adhesive application, minimizes lens misalignment, reduces contact with wiring members, and prolongs the adhesion life, ensuring reliable light reception and improved module performance.
Implementation Method 1
the adhesive agent, the lens holding member and the lens
Data Source
AI summary
This optical sensor module includes: a substrate having an electrode pattern formed on a surface thereof; a photodetector for detecting light, the photodetector being electrically connected to the electrode pattern and being fixed to the substrate; and a lens holding member to which a lens is fixed, the lens holding member being adhered to the substrate by an adhesive agent at such a position as to surround the photodetector, wherein a bottom surface of the lens holding member adhered to the substrate has projections located in a distributed manner, and distal ends of the projections are in contact with the substrate.