Stacked Optocoupler Module with Monolithic Diodes
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Solution Overview
Problem
Existing optocoupler modules lack efficient and compact designs that achieve high voltage and high switching speeds while maintaining mechanical stability and reliable coupling of light signals.
Innovation Solution
A stacked optocoupler module configuration with a transmitter module, a receiver module, and a plate-shaped electrical insulator, where the modules are optically coupled and electrically isolated, with the insulator being transparent to emission wavelengths, and featuring monolithically integrated semiconductor diodes and tunnel diodes connected in series, allowing for direct light coupling and high voltage generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a stacked configuration with plate-shaped insulator is used, then mechanical stability and compactness are improved, but manufacturing precision requirements increase due to alignment of center lines of gravity
Solution Approach 1:
The patent transitions from lateral alignment to vertical stacking configuration, where the transmitter module, insulator, and receiver module are arranged in the thickness direction. This dimensional change allows the center lines of gravity to be aligned vertically through the stacked structure, improving mechanical stability while maintaining manufacturability through standard stacking processes.
2Ease of operation
If the insulator protrudes in a balcony-like manner, then ease of operation and assembly are improved, but device complexity increases
Solution Approach 1:
The plate-shaped insulator serves as an intermediary component between the transmitter module and receiver module. Its balcony-like protrusion creates natural positioning surfaces that facilitate alignment and assembly, while the insulator itself handles the electrical isolation function, simplifying the overall structure by integrating multiple functions into a single component.
3Power
If multiple partial voltage sources are connected in series, then power output is improved, but device complexity increases due to monolithic integration of tunnel diodes
Solution Approach 1:
The patent combines multiple semiconductor diodes with tunnel diodes into a single monolithic integrated structure. This merging allows multiple partial voltage sources to be connected in series within one compact device, achieving high voltage output (above 2V) while reducing the number of separate components and simplifying the overall device structure.
4Reliability
If the offset between center lines of gravity is minimized, then light coupling efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent addresses positioning precision by transitioning to a stacked configuration where alignment occurs in the vertical direction rather than lateral positioning. The center lines of gravity are aligned vertically through the stack, and the balcony-like protrusion of the insulator provides mechanical guidance, reducing the impact of manufacturing tolerances on light coupling efficiency.
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 enables the production of compact optocoupler modules with high switching speeds above 10 MHz, high voltage generation, and increased mechanical stability, while ensuring efficient light coupling and minimal absorption.
Implementation Method 1
the insulator being transparent for at least some of the emission wavelengths of the transmitter module
Implementation Method 2
via the pn junction of the semiconductor diode, the electron-hole pairs generated by the incident light are separated in the space charge region, thereby generating the respective partial voltage
Data Source
Figure 1~5
AI summary
A stacked optocoupler component comprising a transmitter component (S) with a transmitting range (SF), a receiver component (E) with a receiving range (EF), and a plate-shaped electrical isolator (IS), wherein the isolator is formed between the transmitter component and the receiver component. The transmitter component (S), the receiver component (E), and the isolator (IS) are stacked on top of each other, whereby the transmitter component and the receiver component are galvanically isolated from each other but optically coupled to each other. The isolator (IS) is transparent to the emission wavelengths of the transmitter component (E).A center line of gravity on the surface of the transmitting region and a center line of gravity on the surface of the receiving region are essentially parallel to each other, and the offset between the two center lines of gravity is less than half the distance of the respective center lines of gravity to an outer edge of the transmitting region or to an outer edge of the receiving region, such that the light from the transmitting component acts predominantly through the insulator on the receiving component. The receiving component (E) has a number N of partial voltage sources connected in series, where N is a natural number. The deviations of the partial voltages of the individual partial voltage sources from each other are less than 20%. Each of the partial voltage sources has a semiconductor diode (D1 - D4) with a pn junction. A tunnel diode (TD1 - TD3) is formed between each pair of successive partial voltage sources. The partial voltage sources and the tunnel diodes are monolithically integrated together.This novel arrangement makes it possible to produce very compact and small optocoupler modules that have a high switching speed.