Optical Sensor Light Pipe for Inadvertent Triggering
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Solution Overview
Problem
Conventional optical sensors have complex manufacturing processes and are prone to inadvertent triggering due to their structure, which allows undesired light to reach the sensing area.
Innovation Solution
The integration of a light pipe with a light blocking, filtering, focusing, or scattering layer within the optical sensor, filled with optically inert material, to control and direct light to the sensing area, along with a method of manufacture that includes depositing a light blocking material and optical layers to define an aperture around the silicon chip and substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional optical sensor structure with thin housing is used, then the manufacturing process becomes complex and the structure allows inadvertent triggering, but reducing housing thickness was attempted to simplify the design
Solution Approach 1:
A light pipe is introduced as an intermediary component between the sensing area and the housing exterior. The light pipe acts as a controlled light pathway that directs only desired light to the sensing area while blocking undesired light, thereby maintaining sensor reliability without requiring a thick housing structure.
Solution Approach 2:
The housing structure is segmented to include a separate light pipe component that can be independently configured and positioned. This segmentation allows the light pipe to be optimized for light control functionality while the main housing can be kept thin for manufacturing simplicity.
2Object-affected harmful factors
If the housing is made thin to block undesired light, then the structure allows inadvertent triggering of the sensing area, but increasing housing thickness would improve light blocking
Solution Approach 1:
The light pipe serves as a mediator that provides precise light blocking and directing functionality without requiring the entire housing to be thick. The light pipe can be configured with specific optical properties (transmissive, reflective, or scattering) to control light pathways effectively.
Solution Approach 2:
Instead of making the entire housing thick for light blocking, the light pipe is positioned specifically above the sensing area where light control is most critical. This localized approach provides effective light blocking only where needed, reducing overall structural complexity.
3Measurement precision
If a light pipe with filtering layer is added to selectively allow desired wavelengths, then manufacturing complexity increases, but this improves measurement precision
Solution Approach 1:
The light pipe is designed to perform multiple functions: it blocks undesired light, directs desired light to the sensing area, and can incorporate filtering layers for wavelength selection. This multi-functionality consolidates several optical control functions into a single component, managing complexity while improving measurement precision.
Solution Approach 2:
The light pipe can be constructed using composite material structures, such as combining transmissive, reflective, and scattering layers in a single integrated component. This allows the light pipe to achieve complex optical control functions through material composition rather than requiring multiple separate components.
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 enhances the manufacturing simplicity and reduces accidental triggering by selectively allowing desired wavelengths or focusing/scattering light to the sensing area, improving the sensor's operational reliability and accuracy.
Implementation Method 1
light pipe... to control and direct light to the sensing area
Implementation Method 2
light pipe... to control and direct light to the sensing area
Implementation Method 3
light pipe with light blocking, filtering, focusing, or scattering layer
Implementation Method 4
filled with optically inert material... selectively allowing desired wavelengths
Data Source
AI summary
An optical sensor comprising a substrate, a silicon layer having an optical sensor, light block material covering at least portions of said silicon layer and the substrate, defining a light pipe aperture above the optical sensor; and an optical layer positioned within the light pipe aperture. In some embodiments, the light pipe aperture is at least partially filled with a light transmissive material.