Optical module for encoder, encoder, and method for manufacturing optical module for encoder

A method for manufacturing an optical module for an encoder including a support including a bottom wall part, a light receiving element including a light receiving surface, a fiber optical plate including an input surface constituted by surfaces of one end of a plurality of optical fibers and an output surface constituted by surfaces of the other end of the plurality of optical fibers, a first resin member configured to bond the fiber optical plate to the light receiving element, and a second resin member disposed on a surface of the bottom wall part, the method comprising, in the stated order:

• a first step of disposing the light receiving element on the surface of the bottom wall part with the light receiving surface facing a side opposite to the bottom wall part;
• a second step of disposing the fiber optical plate on the light receiving element with the output surface facing the light receiving surface and bonding the fiber optical plate to the light receiving element by the first resin member disposed between the light receiving surface and the output surface;
• and
• a third step of disposing the second resin member on the surface of the bottom wall part so as to be in contact with the light receiving element and the fiber optical plate, wherein
• a material for the first resin member and a material for the second resin member are different from each other, and
• the first resin member is in contact with the light receiving surface and the output surface.

An optical module for an encoder comprising:

• a support including a bottom wall part;
• a light receiving element including a light receiving surface and disposed on a surface of the bottom wall part with the light receiving surface facing a side opposite to the bottom wall part;
• a fiber optical plate including an input surface constituted by surfaces of one end of a plurality of optical fibers and an output surface constituted by surfaces of the other end of the plurality of optical fibers and disposed on the light receiving element with the output surface facing the light receiving surface;
• a first resin member disposed between the light receiving surface and the output surface and configured to bond the fiber optical plate to the light receiving element;
• and
• a second resin member disposed on the surface of the bottom wall part so as to be in contact with the light receiving element and the fiber optical plate, wherein
• a material for the first resin member and a material for the second resin member are different from each other,
• the support further includes a side wall part disposed on the surface of the bottom wall part,
• the side wall part surrounds the light receiving element and the second resin member when viewed from a thickness direction of the bottom wall part, and
• the second resin member is in contact with the side wall part.

An optical module for an encoder comprising:

• a support including a bottom wall part;
• a light receiving element including a light receiving surface and disposed on a surface of the bottom wall part with the light receiving surface facing a side opposite to the bottom wall part;
• a fiber optical plate including an input surface constituted by surfaces of one end of a plurality of optical fibers and an output surface constituted by surfaces of the other end of the plurality of optical fibers and disposed on the light receiving element with the output surface facing the light receiving surface;
• a first resin member disposed between the light receiving surface and the output surface and configured to bond the fiber optical plate to the light receiving element;
• and
• a second resin member disposed on the surface of the bottom wall part so as to be in contact with the light receiving element and the fiber optical plate, wherein
• a material for the first resin member and a material for the second resin member are different from each other, and
• an outer edge of the first resin member overlaps an outer edge of the fiber optical plate when viewed from a thickness direction of the bottom wall part.

An optical module for an encoder comprising:

• a support including a bottom wall part;
• a light receiving element including a light receiving surface and disposed on a surface of the bottom wall part with the light receiving surface facing a side opposite to the bottom wall part;
• a fiber optical plate including an input surface constituted by surfaces of one end of a plurality of optical fibers and an output surface constituted by surfaces of the other end of the plurality of optical fibers and disposed on the light receiving element with the output surface facing the light receiving surface;
• a first resin member disposed between the light receiving surface and the output surface and configured to bond the fiber optical plate to the light receiving element;
• and
• a second resin member disposed on the surface of the bottom wall part so as to be in contact with the light receiving element and the fiber optical plate, wherein
• a material for the first resin member and a material for the second resin member are different from each other, and
• a light transmittance of the second resin member is lower than a light transmittance of the first resin member.

An optical module for an encoder comprising:

• a support including a bottom wall part;
• a light receiving element including a light receiving surface and disposed on a surface of the bottom wall part with the light receiving surface facing a side opposite to the bottom wall part;
• a fiber optical plate including an input surface constituted by surfaces of one end of a plurality of optical fibers and an output surface constituted by surfaces of the other end of the plurality of optical fibers and disposed on the light receiving element with the output surface facing the light receiving surface;
• an anti-reflective layer formed on the input surface of the fiber optical plate;
• a first resin member disposed between the light receiving surface and the output surface and configured to bond the fiber optical plate to the light receiving element;
• and
• a second resin member disposed on the surface of the bottom wall part so as to be in contact with the light receiving element and the fiber optical plate, wherein
• a material for the first resin member and a material for the second resin member are different from each other.

An optical module for an encoder comprising:

• a support including a bottom wall part;
• a light receiving element including a light receiving surface and disposed on a surface of the bottom wall part with the light receiving surface facing a side opposite to the bottom wall part;
• a fiber optical plate including an input surface constituted by surfaces of one end of a plurality of optical fibers and an output surface constituted by surfaces of the other end of the plurality of optical fibers and disposed on the light receiving element with the output surface facing the light receiving surface;
• a first resin member disposed between the light receiving surface and the output surface and configured to bond the fiber optical plate to the light receiving element;
• and
• a second resin member disposed on the surface of the bottom wall part so as to be in contact with the light receiving element and the fiber optical plate, wherein
• a material for the first resin member and a material for the second resin member are different from each other,
• the fiber optical plate includes a pair of side surfaces facing opposite sides to each other in a direction perpendicular to a thickness direction of the bottom wall part, and
• the second resin member is in contact with both of the pair of side surfaces.

An encoder comprising:

• a rotary plate including a light passage pattern or a light reflection pattern;
• and
• an optical module comprising:
• a support including a bottom wall part;
• a light receiving element including a light receiving surface and disposed on a surface of the bottom wall part with the light receiving surface facing a side opposite to the bottom wall part;
• a fiber optical plate including an input surface constituted by surfaces of one end of a plurality of optical fibers and an output surface constituted by surfaces of the other end of the plurality of optical fibers and disposed on the light receiving element with the output surface facing the light receiving surface;
• a first resin member disposed between the light receiving surface and the output surface and configured to bond the fiber optical plate to the light receiving element;
• and
• a second resin member disposed on the surface of the bottom wall part so as to be in contact with the light receiving element and the fiber optical plate, wherein
• a material for the first resin member and a material for the second resin member are different from each other, and
• the optical module is disposed with light passing through the light passage pattern or light reflected by the light reflection pattern being incident on the light receiving element.

A method for manufacturing an optical module for an encoder including a support including a bottom wall part, a light receiving element including a light receiving surface, a fiber optical plate including an input surface constituted by surfaces of one end of a plurality of optical fibers and an output surface constituted by surfaces of the other end of the plurality of optical fibers, a first resin member configured to bond the fiber optical plate to the light receiving element, and a second resin member disposed on a surface of the bottom wall part, the method comprising, in the stated order:

• a first step of disposing the light receiving element on the surface of the bottom wall part with the light receiving surface facing a side opposite to the bottom wall part;
• a second step of disposing the fiber optical plate on the light receiving element with the output surface facing the light receiving surface and bonding the fiber optical plate to the light receiving element by the first resin member disposed between the light receiving surface and the output surface;
• and
• a third step of disposing the second resin member on the surface of the bottom wall part so as to be in contact with the light receiving element and the fiber optical plate, wherein
• a material for the first resin member and a material for the second resin member are different from each other,
• in the second step, the fiber optical plate is bonded to the light receiving element by curing the first resin member,
• in the third step, the second resin member is disposed on the surface of the bottom wall part and then cured, and
• a viscosity of the first resin member before being cured in the second step is lower than a viscosity of the second resin member before being cured in the third step.

A method for manufacturing an optical module for an encoder including a support including a bottom wall part, a light receiving element including a light receiving surface, a fiber optical plate including an input surface constituted by surfaces of one end of a plurality of optical fibers and an output surface constituted by surfaces of the other end of the plurality of optical fibers, a first resin member configured to bond the fiber optical plate to the light receiving element, and a second resin member disposed on a surface of the bottom wall part, the method comprising, in the stated order:

• a first step of disposing the light receiving element on the surface of the bottom wall part with the light receiving surface facing a side opposite to the bottom wall part;
• a second step of disposing the fiber optical plate on the light receiving element with the output surface facing the light receiving surface and bonding the fiber optical plate to the light receiving element by the first resin member disposed between the light receiving surface and the output surface;
• and
• a third step of disposing the second resin member on the surface of the bottom wall part so as to be in contact with the light receiving element and the fiber optical plate, wherein
• a material for the first resin member and a material for the second resin member are different from each other,
• the method further comprising a forming step of forming the fiber optical plate before the second step, wherein
• the forming step includes, in the stated order:
• a step of attaching a second substrate including a plurality of portions corresponding to the first resin member to a first substrate including a plurality of portions corresponding to the fiber optical plate, and
• a step of cutting the first substrate and the second substrate to acquire a plurality of the fiber optical plates attached with the first resin member.

A method for manufacturing an optical module for an encoder including a support including a bottom wall part, a light receiving element including a light receiving surface, a fiber optical plate including an input surface constituted by surfaces of one end of a plurality of optical fibers and an output surface constituted by surfaces of the other end of the plurality of optical fibers, a first resin member configured to bond the fiber optical plate to the light receiving element, and a second resin member disposed on a surface of the bottom wall part, the method comprising, in the stated order:

• a first step of disposing the light receiving element on the surface of the bottom wall part with the light receiving surface facing a side opposite to the bottom wall part;
• a second step of disposing the fiber optical plate on the light receiving element with the output surface facing the light receiving surface and bonding the fiber optical plate to the light receiving element by the first resin member disposed between the light receiving surface and the output surface;
• and
• a third step of disposing the second resin member on the surface of the bottom wall part so as to be in contact with the light receiving element and the fiber optical plate, wherein
• a material for the first resin member and a material for the second resin member are different from each other,
• a third substrate including a plurality of bottom wall portions corresponding to the bottom wall part is used,
• in the first step, for each of the plurality of bottom wall portions, the light receiving element is disposed on the surface of the bottom wall part with the light receiving surface facing a side opposite to the bottom wall part,
• in the second step, for each of the plurality of bottom wall portions, the fiber optical plate is disposed on the light receiving element with the output surface facing the light receiving surface and the fiber optical plate is bonded to the light receiving element by the first resin member disposed between the light receiving surface and the output surface,
• in the third step, for each of the plurality of bottom wall portions, the second resin member is disposed on the surface of the bottom wall part so as to be in contact with the light receiving element, the first resin member, and the fiber optical plate, and
• the method for manufacturing an optical module for an encoder further comprises a fourth step of cutting the third substrate to acquire a plurality of the optical modules for an encoder after the third step.