TO-CAN Cap Adhesive-Free Mechanical Interlock
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Solution Overview
Problem
Existing TO-CAN caps in optical communication devices face challenges in achieving optimal light transmission efficiency and assembly cost reduction due to complex adhesive-based assembly processes.
Innovation Solution
A TO-CAN cap design featuring a hollow cylindrical casing with a protrusion portion and an optical lens with a rib portion, connected without adhesives, utilizing specific thickness and refractive index ratios to enhance light coupling efficiency and facilitate assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive-based assembly process is used to connect casing and optical lens, then assembly strength is improved, but assembly complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates the adhesive from the assembly system by designing a mechanical connection structure. The protrusion portion on the casing fits into a corresponding recess on the optical lens, creating a direct mechanical interlock that replaces the need for adhesive bonding, thereby simplifying the assembly process while maintaining connection strength
Solution Approach 2:
The patent replaces the chemical bonding mechanism (adhesive) with a mechanical bonding mechanism (protrusion-recess interlock). This substitution eliminates the need for adhesive application, curing time, and associated quality control steps, reducing assembly complexity and cost while maintaining or improving connection reliability
2Reliability
If complex adhesive-based assembly process is used, then connection reliability is improved, but assembly time and cost increase
Solution Approach 1:
The protrusion and recess features are pre-formed during the manufacturing of the casing and optical lens components. This preliminary action ensures that when the components are assembled, the mechanical interlock is immediately established without requiring additional steps for alignment or bonding, reducing assembly time while ensuring reliable connection
Solution Approach 2:
The mechanical interlock structure is designed to be self-aligning and self-securing. The protrusion portion naturally guides the optical lens into the correct position and the interlocking geometry automatically provides the connection force, eliminating the need for external adhesive application and curing processes
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
The design achieves reduced assembly costs and improved light transmission efficiency by allowing adhesive-free connection of the casing and optical lens, optimizing focal lengths, refractive indices, and surface curvatures for better aberration correction and coupling efficiency.
Implementation Method 1
light emitted from the optical luminescent device enclosed by the TO-CAN cap is converged by a lens in the cap and subsequently incident on the fiber end
Data Source
AI summary
The present disclosure provides a TO-CAN cap. The TO-CAN cap includes a casing, the casing has a hollow cylindrical structure, and an inner wall of the casing has a protrusion portion at a first end portion in an axial direction of the casing; and an optical lens, the optical lens has an optical portion for refracting light and a rib portion at a periphery of the optical portion, a side surface of the rib portion having a concave portion complementary to the protrusion portion, where the casing and the optical lens are connected to each other through the protrusion portion and the concave portion.