Non-contact Optical Sensor Module Compact Design
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Solution Overview
Problem
Conventional optical sensor modules are too thick for small-sized electronic devices like mobile phones due to the vertical alignment of the object surface, lens system, and image sensor, which limits their integration and increases the device's height.
Innovation Solution
An optical sensor module with a flexible printed circuit board (FPCB) and a sag lens with a short focal distance, where infrared LEDs emit light upward, and the image sensor is closely attached to the bottom surface, eliminating the need for a separate barrel structure and allowing for a compact design with a height of 0.7 to 2.0 mm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the object surface, lens system, and image sensor are aligned vertically with the optical axis, then the optical sensor module can detect object motion, but the height of the module increases
Solution Approach 1:
The patent transitions from a vertical alignment configuration to a horizontal alignment configuration. The object surface, lens system, and image sensor are arranged side-by-side along the optical axis direction rather than stacked vertically, effectively changing the dimensional arrangement from vertical to horizontal, thereby reducing module height while maintaining detection functionality
Solution Approach 2:
The patent employs asymmetric arrangement of components where the object surface, lens system, and image sensor are positioned at different heights relative to the optical axis, creating an asymmetric configuration that allows compact vertical stacking while maintaining proper optical alignment and detection capability
2Manufacturing precision
If a conventional optical sensor module structure is used, then the lens system can focus light, but the module height increases due to separate barrel and housing structures
Solution Approach 1:
The patent merges the previously separate barrel structure and housing into a single integrated housing structure. The housing simultaneously serves as both the barrel for mounting the lens system and the outer housing for the entire module, eliminating the need for separate components and reducing overall module height
Solution Approach 2:
The housing is designed to perform multiple functions: it serves as the structural frame, the barrel for lens mounting, and the protective enclosure. This multi-functional design eliminates redundant components and reduces the overall module height while maintaining light focusing capability
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
Enables a non-contact button function on mobile devices by detecting the motion of objects using infrared LEDs and a short focal length lens, facilitating the integration of optical sensors into small-sized electronic devices without increasing their height.
Implementation Method 1
light from a light source is irradiated downward
Implementation Method 2
light irradiated onto the cover glass 11 is reflected by the object
Implementation Method 3
a lens is positioned in a lower portion of the optical image sensor such that a cursor on the screen is moved by the motion of the optical mouse
Data Source
AI summary
Provided is an optical sensor module including a printed circuit board (PCB) having a pad with a perforated portion formed in the central portion thereof; a lens disposed on the top surface of the pad so as to cover the perforated portion; one or more light sources disposed around the lens; an image sensor closely attached to the bottom surface of the pad; and a housing mounted to surround the outer periphery of the image sensor, the housing having the same height as that of the image sensor and the same size as that of the pad.