Integrated Sensor Substrate Curving for Alignment
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Solution Overview
Problem
In rotary encoders and similar sensors, misalignment between light emitting and receiving devices on separate substrates leads to instability in output due to errors in positioning, especially when multiple light receiving devices are used, causing variations in output and detection instability.
Innovation Solution
A sensor manufacturing method where the light emitting and receiving devices are integrated on a single substrate, allowing for easier positioning by curving or bending the substrate, and relative movement of the substrate and motion body to ensure proper alignment within the sensor housing, facilitating accurate detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If light emitting device and light receiving device are installed on different substrates, then device complexity is reduced and manufacturing is easier, but positioning precision deteriorates and output stability becomes poor
Solution Approach 1:
The patent merges the light emitting device and light receiving device onto a single substrate, eliminating the need for separate substrate assembly and positioning. This integration ensures precise alignment between the light emitting area and light receiving area, resolving the positioning precision issue while maintaining manufacturing simplicity through a unified substrate structure.
2Device complexity
If positioning is performed during assembly of separate substrates, then device complexity is reduced, but manufacturing precision deteriorates due to alignment errors
Solution Approach 1:
The patent implements preliminary positioning by pre-defining the relative positions of light emitting and light receiving areas on the same substrate during the substrate manufacturing stage. This preliminary action eliminates the need for complex alignment operations during final assembly, ensuring high positioning precision without increasing assembly complexity.
3Adaptability or versatility
If multiple light receiving devices are used, then detection capability is improved, but output stability deteriorates due to misalignment variations
Solution Approach 1:
The patent integrates multiple light receiving devices on a single substrate with the light emitting device, ensuring uniform and precise positioning relative to the light source. This integration maintains consistent alignment across all light receiving devices, enabling enhanced detection capability through multiple sensors while preserving output stability by eliminating misalignment variations that would occur with separate substrate assembly.
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 method simplifies the positioning and manufacturing process, reduces output variations, and enhances the accuracy of sensing by ensuring precise alignment and sealing of the generator, detector, and motion body within the sensor housing.
Implementation Method 1
a light emitting device, which emits light
Implementation Method 2
a light receiving device, which detects the light emitted by the light emitting device
Data Source
AI summary
A sensor manufacturing method is a method for manufacturing a sensor including a generator that generates a predetermined detection target, a detector that detects the detection target generated by the generator, and a motion body that performs motion in the area in between the generator and the detector. In the method, the generator and the detector are positioned opposite to each other by either curving or bending a substrate including a first portion having the generator installed thereon and a second portion having the detector installed thereon that are formed in an integrated manner, and the substrate and the motion body are made to perform relative movement in such a way that the motion body enters the area in between the generator and the detector.