Optical Sensor Module Lead Frame Light Leakage Prevention

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Solution Overview

Problem

Conventional optical sensor modules for photoplethysmography (PPG) face issues with light leakage due to ineffective light-blocking structures and poor heat dissipation, which affect measurement accuracy.

Innovation Solution

An optical sensor module design featuring a lead frame with a main plate and side plates, where the light-receiver is positioned on the main plate and light-emitters are on the side plates, with a housing molded over the lead frame to create effective light-blocking walls and enhance heat dissipation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a light-blocking wall is added to separate the light-receiver from the light-emitters, then light leakage is reduced, but the structural complexity increases

Engineering Contradiction:
Improvelight leakageVSAvoidstructural complexity
Core Design Contradiction:
Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent merges the light-blocking function with the existing structural components by making the housing itself serve as the light-blocking wall. The housing is designed with light-blocking properties and positioned to naturally separate the light-receiver from the light-emitters, eliminating the need for additional dedicated light-blocking components. This integration reduces structural complexity while maintaining effective light leakage prevention.

Inventive Principle:
Principle #5Merging (Combining)

2Ease of manufacture

If the PCB is used as the base structure, then manufacturing is simplified, but heat dissipation performance deteriorates

Engineering Contradiction:
Improvemanufacturing simplicityVSAvoidheat dissipation
Core Design Contradiction:
Ease of manufactureVSTemperature

Solution Approach 1:

The patent employs a composite structure where the housing is made from a material with superior heat dissipation properties compared to the PCB. The housing serves dual purposes: providing structural support and acting as a heat dissipation pathway. This composite approach allows the module to maintain manufacturing simplicity while significantly improving heat dissipation performance through the strategic use of thermally conductive materials in the housing.

Inventive Principle:
Principle #40Composite materials

3Volume of moving object

If the light-receiver and light-emitters are placed close together for compact design, then device size is reduced, but light interference increases

Engineering Contradiction:
Improvedevice sizeVSAvoidlight interference
Core Design Contradiction:
Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by creating a light-blocking environment specifically in the regions between the light-receiver and light-emitters, while maintaining their close proximity for compactness. The housing is designed with light-blocking walls positioned strategically to block direct light paths from emitters to receiver, while allowing the components to remain closely spaced. This localized light-blocking approach enables compact device size without sacrificing performance by preventing light interference.

Inventive Principle:
Principle #3Local quality

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 design effectively prevents light leakage, improves signal-to-noise ratio, and enhances heat dissipation, leading to more accurate PPG signal recording.

Implementation Method 1

the light-emitters 13 emit light to irradiate a biological body, and the light-receiver 12 receives the light reflected from or transmitting through the biological body and produces an optical signal representative of a physiological status of the biological body

Methodology Applied
Scientific EffectPhotoelectric Effect: Photoelectric Effect

Implementation Method 2

the housing is molded over the lead frame... effectively prevents light leakage

Methodology Applied
Scientific EffectLight blocking: Absorption (EM radiation)

Data Source

PatentUS10686096B2Optical sensor module and a wearable device including the same
Publication Date: 2020.06.16 LITE ON OPTO TECH (CHANGZHOU) CO LTD
  • US10686096B2 patent drawing
  • US10686096B2 patent drawing
  • US10686096B2 patent drawing

AI summary

A lead frame includes a main plate and a side plate. The main plate has a support portion and a projecting portion. The support portion has two opposite first sides and a support face located between the first sides. The projecting portion projects upward from one of the first sides in a direction opposite to the support face. The side plate is disposed separately from the one of the first sides of the support portion and is spaced apart from the projecting portion.