Photosensor Lead Protrusion for Compact Optical Alignment
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Solution Overview
Problem
Existing photosensor designs fail to achieve a configuration where both emitter and receiver leads protrude from the circuit-encapsulating portion in a direction intersecting with the direction of external connecting terminals.
Innovation Solution
The photosensor design includes first and second emitter leads and receiver leads that are flat plates, bent to protrude from the circuit-encapsulating portion in a direction parallel to a specific plane, allowing them to intersect with the direction of external connecting terminals, enabling the light emitter and receiver to face each other while maintaining easy fabrication and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the emitter and receiver leads are arranged to protrude in a direction intersecting with the connecting terminals, then the design flexibility and compactness are improved, but the structural complexity and manufacturing difficulty increase
Solution Approach 1:
The patent transitions from a conventional planar arrangement where all components lie in the same plane to a three-dimensional configuration where emitter and receiver leads protrude in a direction intersecting with connecting terminals. This dimensional change allows the light emitter and receiver to face each other while maintaining compact size, resolving the contradiction between design flexibility and structural complexity.
Solution Approach 2:
The emitter and receiver leads are designed with curved or bent configurations rather than straight lines. The leads extend from the circuit-encapsulating portion in intersecting directions and are deformed to allow proper positioning, using curvature to achieve the required spatial arrangement while managing structural complexity.
2Volume of moving object
If the emitter and receiver leads are deformed to allow proper positioning, then the compactness and space utilization are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The emitter and receiver leads are pre-deformed during the manufacturing process to their final curved configurations. By performing the deformation action in advance during fabrication rather than requiring precise positioning during assembly, the patent achieves compact arrangement while managing positioning precision requirements through preliminary shaping.
3Loss of substance
If the leads are arranged in intersecting directions, then the material usage is reduced, but the ease of manufacture decreases
Solution Approach 1:
The lead structure is divided into multiple segments: connecting terminals extending in a first direction, and emitter/receiver leads protruding in intersecting directions. This segmentation allows each portion to be optimized independently, reducing overall material usage while managing fabrication complexity through modular construction of the leadframe.
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 allows for a compact and efficient sensor module structure where the emitter and receiver leads protrude in a direction intersecting with the external connecting terminals, enhancing design flexibility and reducing material usage while ensuring easy assembly.
Implementation Method 1
a light emitter 10... The light receiver 15 receives light from the light emitter 10
Implementation Method 2
a light receiver 15... The light receiver 15 receives light from the light emitter 10 and outputs a light receiving signal
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A photosensor includes a sensor module (5) in which emitter leads (20, 22) and receiver leads (24, 26) protrude from a circuit-encapsulating portion (90) in a direction intersecting with a direction (Y) in which an external connecting terminal (50) extends. The photosensor includes a light emitter (10), a light receiver (15), a circuit-encapsulating portion (90), a connecting terminal (50), first and second emitter leads (20, 22), and first and second receiver leads (24, 26). When the connecting terminal (50) extends in a first direction (Y), and a first plane (X,Y) is parallel to the first direction, the first and second emitter leads (20, 22) protrude from the circuit-encapsulating portion (90) in a direction parallel to the first plane (X,Y) and intersecting with the first direction (Y), and extend opposite to the first direction. The first and second receiver leads (24, 26) protrude from the circuit-encapsulating portion (90) in the direction parallel to the first plane (X,Y) and intersecting with the first direction (Y) and opposite to a direction in which the first and second emitter leads protrude, and extend opposite to the first direction. The first and second emitter leads (20, 22) and the first and second receiver leads (24, 26) are deformed to allow the light receiver (15) and the light emitter (10) to face each other.