Photocoupler Lead Frame Sheet Alignment via Pilot Pins
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing photocouplers using two separate lead frame sheets face challenges in accurately positioning the light emitting and light receiving side lead frames, leading to inefficiencies in material utilization and increased fabrication costs.
Innovation Solution
A method involving a lead frame sheet with alternately arranged light emitting and receiving column portions, interconnected by linking portions and featuring pilot holes and coupling bars, which allows for precise positioning and alignment of the lead frames using pilot pins, enabling accurate opposition and connection of the light emitting and receiving devices within a resin body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two separate lead frame sheets are used for light emitting and light receiving devices, then the fabrication process can be simplified, but the positioning accuracy between light emitting and light receiving side lead frames deteriorates
Solution Approach 1:
The patent combines both light emitting side lead frames and light receiving side lead frames into a single integrated lead frame sheet. This merging allows precise positioning through fixed geometric relationships and coupling bar connections, while maintaining fabrication simplicity through unified processing steps.
Solution Approach 2:
The patent introduces coupling bars as intermediary elements that connect the light emitting and light receiving side lead frames. These coupling bars serve as mediators that enable accurate positioning and alignment between the two functional sides, resolving the positioning accuracy issue while keeping the overall structure integrated.
2Loss of substance
If both light emitting and light receiving side lead frames are formed in one lead frame sheet, then material utilization efficiency is improved, but positioning accuracy between light emitting and light receiving side lead frames deteriorates
Solution Approach 1:
By forming both light emitting and light receiving side lead frames in a single integrated sheet, the patent maximizes material utilization. The merging approach allows continuous material usage without cutting and repositioning, eliminating waste while maintaining precision through the coupling bar connection system.
Solution Approach 2:
The coupling bars act as intermediary connection elements that enable precise positioning between the light emitting and light receiving side lead frames within the same sheet. This mediator system ensures accurate alignment is achieved despite the integrated structure, resolving the positioning accuracy challenge.
3Loss of substance
If light emitting side lead frame is cut off and opposed to light receiving side lead frame, then material utilization is improved, but positioning accuracy and alignment precision deteriorate
Solution Approach 1:
Instead of cutting and separating the lead frames, the patent merges them into a single continuous sheet structure. This eliminates the need for cutting operations that cause positioning errors, while still achieving material efficiency through the integrated design that uses the entire sheet effectively.
Solution Approach 2:
The coupling bars serve as intermediary connection elements that provide fixed geometric relationships between the light emitting and light receiving side lead frames. This mediator system ensures precise alignment is maintained without requiring cutting and repositioning operations.
Data Source
AI summary
A method for manufacturing a photocoupler includes: mounting light emitting devices and light receiving devices on a lead frame sheet; positioning the lead frame sheet with respect to a die by cutting off the one set of column portions from a linking portion and inserting a first pilot pin formed on the die into a second pilot hole; opposing the light emitting devices and the light receiving devices to each other; connecting the light emitting side coupling bars and the light receiving side coupling bars to each other on the die; forming a resin body so as to cover a pair of the light emitting device and the light receiving device; and cutting off the light emitting side lead frame portion from the light emitting column portion and cutting off the light receiving side lead frame portion from the light receiving column portion.