Photosensor Resin Molding with Light Diffusing Agent

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Solution Overview

Problem

The existing photosensor molding process is complicated due to the need for separate resins with different light diffusing properties for the emitter, receiver, and operation indicator elements, which affects light detection and visibility.

Innovation Solution

A photosensor design where the emitter, receiver, and operation indicator elements are encapsulated with the same resin material containing a light diffusing agent, connected by a conductive leadframe, allowing for a single molding process and optimizing light transmittance between 20% and 60% to enhance visibility and detection accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If the resin encapsulating the emitter element and receiver element contains a large amount of light diffusing agent, then the visibility of the operation indicator lamp is improved, but the amount of light reaching the receiver element is reduced

Engineering Contradiction:

Improvevisibility of operation indicator lampVSAvoidlight detection accuracy

Core Design Contradiction:

Illumination intensityVSReliability

Solution Approach 1:

The patent divides the resin into two separate encapsulation portions: a first resin encapsulating the emitter and receiver elements, and a second resin encapsulating the luminous element. This segmentation allows each resin to have optimized light diffusing agent content for its specific function, resolving the contradiction between visibility and detection accuracy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the resin are given different properties: the first resin has lower light diffusing agent content (10-30% by weight) to maintain detection accuracy, while the second resin has higher light diffusing agent content to maximize visibility of the operation indicator lamp. This local quality differentiation resolves the contradiction.

Inventive Principle:

Principle #3Local quality

2Illumination intensity

Engineering Contradiction:

Improvevisibility of operation indicator lampVSAvoidambient light interference

Core Design Contradiction:

Illumination intensityVSObject-affected harmful factors

Solution Approach 1:

The patent segments the resin into two distinct encapsulation materials with different light diffusing agent contents. The first resin protects the detection elements from ambient light interference, while the second resin enhances visibility, resolving the contradiction between visibility improvement and ambient light resistance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first resin is designed with controlled light diffusing properties to resist ambient light interference, while the second resin is designed with high light diffusing properties for visibility. This local quality assignment resolves the contradiction between visibility and ambient light resistance.

Inventive Principle:

Principle #3Local quality

3Reliability

If separate resins are used for encapsulating the emitter-receiver elements and the luminous element, then the intended performance for each resin is achieved, but the molding process is complicated

Engineering Contradiction:

Improveresin performance optimizationVSAvoidmolding process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

While maintaining segmentation of resin functions, the patent integrates the molding process by using a common base resin material for both encapsulation portions. This allows separate performance optimization through controlled addition of light diffusing agents while simplifying the molding process through material uniformity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses the same base resin material for both first and second encapsulation resins, making the resin material universal. Different light diffusing agent contents provide different functions, achieving performance optimization without complicating the molding process through material variety.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Measurement precision

If no light diffusing agent is used in the resin encapsulating the emitter element and receiver element, then the detection accuracy is maintained, but the visibility of the operation indicator lamp is reduced

Engineering Contradiction:

Improvedetection accuracyVSAvoidvisibility of operation indicator lamp

Core Design Contradiction:

Measurement precisionVSIllumination intensity

Solution Approach 1:

The patent segments the resin system into two parts: the first resin with controlled light diffusing agent content for detection accuracy, and the second resin with high light diffusing agent content for visibility. This segmentation allows both requirements to be satisfied simultaneously.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first resin is designed with specific light diffusing properties for accurate detection, while the second resin is designed with high light diffusing properties for visibility. This local quality assignment resolves the contradiction between detection accuracy and visibility.

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

This approach simplifies the molding process while maintaining the necessary light transmittance for effective light detection and visibility of the operation indicator, reducing the impact of ambient light on the detection system.

Implementation Method 1

the resin encapsulating the emitter element and a receiver element contains 10% to 30% by weight of light diffusing agent

Methodology Applied

Scientific EffectLight diffusion: Scattering

Data Source

PatentEP2919281B1photosensor

Publication Date: 2020.01.15 OMRON CORP

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AI summary

A photosensor simplifies the resin molding process for an emitter element (11), a receiver element (16), and a luminous element (42) forming an operation indicator lamp. The photosensor includes an emitter element (11), an emitter-encapsulating portion (12), a receiver element (16), a receiver-encapsulating portion (17), a circuit portion (40), and a circuit-encapsulating portion (90). The emitter-encapsulating portion (12) encapsulates the emitter element (11). The receiver-encapsulating portion (17) encapsulates the receiver element (16). The circuit portion (40) includes a luminous element (42) for indicating an operation. The circuit-encapsulating portion (90) encapsulates the circuit portion. The circuit-encapsulating portion includes an operation indicator (92) portion facing the luminous element. The emitter-encapsulating portion (12), the receiver-encapsulating portion (17), and the circuit-encapsulating portion (90) are connected to one another with a conductive leadframe (8). The emitter-encapsulating portion (12), the receiver-encapsulating portion (17), and the circuit-encapsulating portion (90) are formed from the same resin material containing a light diffusing agent.