Opto-coupler Lens Assembly for Compact Footprint
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Solution Overview
Problem
Current opto-couplers have inefficiencies and a large footprint, making them costly and difficult to manufacture efficiently, while also requiring high power optical transmitters and lacking in compact multichannel configurations.
Innovation Solution
The use of a lens assembly positioned between dielectric and adhesive materials to focus light efficiently between an optical transmitter and receiver, allowing for compact designs, reduced power consumption, and cost-effective multi-channel configurations, with the lens assembly comprising multiple lenses aligned in planes to enhance coupling performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional opto-coupler designs are used, then electrical isolation is provided, but the current footprint is large and manufacturing is costly and inefficient
Solution Approach 1:
The opto-coupler is divided into separate functional modules: an optical transmitter module with LED and lens, an optical receiver module with photodetector, and intermediate transfer elements. This segmentation allows each module to be optimized independently for manufacturing efficiency while reducing the overall footprint through compact arrangement of discrete components
Solution Approach 2:
The lens is positioned within the optical transmitter module in a nested configuration with the LED, and the entire transmitter module is integrated with the receiver module in a compact stacked arrangement. This nesting allows multiple optical components to occupy overlapping or adjacent spaces, reducing the total current footprint while maintaining manufacturing simplicity
2Reliability
If high power optical transmitters are used, then signal transfer is achieved, but power consumption is high and Bill of Material costs increase
Solution Approach 1:
A lens is introduced as an intermediary optical element between the LED and the photodetector. This lens focuses and directs the light path, improving the coupling efficiency of light transfer. As a result, lower power LEDs can achieve the same signal transfer reliability, reducing overall power consumption and BOM costs
Solution Approach 2:
The optical system parameters are optimized by adjusting the lens focal length, curvature, and material properties to maximize light coupling efficiency. By changing these optical parameters, the system achieves reliable signal transfer with reduced LED power requirements, directly addressing the power consumption issue
3Area of stationary object
If compact designs are implemented, then footprint is reduced, but manufacturing complexity increases
Solution Approach 1:
The compact design is achieved through segmentation into standardized modules (transmitter, receiver, lens assembly) that can be manufactured separately using simple processes and then assembled. This modular segmentation reduces the footprint while keeping each module's internal structure simple and easy to manufacture
Solution Approach 2:
The lens assembly is designed as a universal component that serves multiple functions: focusing light, defining the optical path, and providing mechanical alignment references for the LED and photodetector. This multi-functionality reduces the number of separate alignment features needed, simplifying the overall structure despite the compact footprint
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 minimizes the need for high power optical transmitters, reduces Bill of Material costs, and improves high voltage performance by enabling efficient light focusing and signal transfer, while supporting higher voltage operations and compact designs.
Implementation Method 1
The lens assembly is configured to focus light emitted from an optical transmitter to an optical receiver
Implementation Method 2
a source (emitter) of light, usually a near infrared light-emitting diode (LED), that converts an electrical input signal into light
Implementation Method 3
a photosensor, which detects incoming light and either generates electric energy directly, or modulates electric current flowing from an external power supply
Data Source
AI summary
A semiconductor device and methods of manufacturing the same are disclosed. Specifically, methods and devices for manufacturing opto-couplers are disclosed. Even more specifically, the opto-coupler includes a lens assembly to enhance light coupling efficiency between an optical transmitter and an optical receiver. An encapsulant material may also be utilized.