Optical Sensor Dual Resin Body Durability

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Solution Overview

Problem

Existing optical sensors and proximity sensors mounted on robot hands face durability issues due to the use of elastic bodies that deform under external forces, affecting the light receiving portion and reducing sensor reliability.

Innovation Solution

The design incorporates a light emitter and receiver covered by a first resin body that transmits light and is surrounded by a second resin body, which is harder and seals the components, reducing direct strain on the light emitter and receiver, and improving durability by using a harder second resin body inside the first resin body.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If an elastic body is provided on the light receiving portion to enable deformation sensing, then the sensor can detect contact and proximity, but the light receiving portion is directly influenced by distortion and durability is reduced

Engineering Contradiction:

Improvecontact and proximity detection capabilityVSAvoidsensor durability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The sensor is divided into two distinct resin bodies with different hardness: a first resin body that deforms to enable sensing, and a second resin body that remains stable to protect the light receiving portion. This segmentation allows each component to fulfill its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the sensor have different mechanical properties. The first resin body has softer, more deformable properties for sensing, while the second resin body has harder, more stable properties for protection. This local differentiation of material properties resolves the contradiction between adaptability and reliability.

Inventive Principle:

Principle #3Local quality

2Reliability

If a harder resin body is used to protect the light receiving portion from deformation, then durability is improved, but the sensor cannot detect external forces effectively

Engineering Contradiction:

Improvesensor durabilityVSAvoidexternal force detection capability

Core Design Contradiction:

ReliabilityVSForce

Solution Approach 1:

The sensor structure is segmented into a force-receiving portion (first resin body) and a light-receiving portion (second resin body). The first resin body deforms under external force while the second resin body remains stable, allowing both force detection and protection of the light receiving portion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first resin body acts as an intermediary between the external environment and the light receiving portion. It transmits the effect of external forces to the light receiving portion through deformation while protecting it from direct mechanical damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Measurement precision

If the light receiving portion is directly exposed to the external environment for proximity sensing, then sensing accuracy is maintained, but the sensor is vulnerable to environmental damage

Engineering Contradiction:

Improveproximity sensing accuracyVSAvoidenvironmental damage vulnerability

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The first resin body functions as a flexible protective shell that covers and protects the light receiving portion while allowing optical signals to pass through. This shell provides mechanical protection without compromising the sensing function.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The first resin body serves as an intermediary layer between the external environment and the light receiving portion, filtering out harmful mechanical factors while allowing light transmission for accurate proximity sensing.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 durability and reliability of optical and proximity sensors by minimizing deformation from external forces and maintaining accurate light detection, even under varying loads and temperatures.

Implementation Method 1

a first resin body that covers the light emitter and the light receiver to transmit the light emitted from the light emitter and emit the light outside

Methodology Applied

Scientific EffectLight transmission: Light

Implementation Method 2

a second resin body that seals the light emitter and the light receiver, wherein the second resin body is included inside the first resin body

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS11698295B2Optical sensor including a hard resin and a soft resin and proximity sensor including the same

Publication Date: 2023.07.11 MURATA MFG CO LTD

AI summary

An optical sensor includes a light emitter to emit light, a light receiver to receive the light emitted from the light emitter, a first resin body that covers the light emitter and the light receiver to transmit the light emitted from the light emitter to emit the light outside, and a second resin body that seals the light emitter and the light receiver, in which the second resin body is included inside the first resin body, and the second resin body is harder than the first resin body.