Abstract:
A clamp for holding at least one laser component during a facet coating process. The clamp includes a first elongate member for contacting a first side of the laser component(s) and a second elongate member for contacting a second opposing side of the laser component(s). The clamp also includes spacers disposed between and abutting the laser component(s). The first and second elongate members hold the laser component(s) and the spacers therebetween.

Description:
RELATED APPLICATIONS  
       [0001]    This application is related to commonly-assigned U.S. application entitled “Improved Laser Bar Clamp” (Attorney&#39;s Docket Number: Fox 1). 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention relates to a clamp, and in particular, a clamp for holding electrical components.  
         DESCRIPTION OF THE RELATED ART  
         [0003]    During the production of electrical components, it is often necessary to hold the components during different stages of manufacture. For example, during the production of laser bars and laser chips (collectively laser components) it is often necessary to hold the laser components during a facet coating process. The facet coating process entails coating different portions of the laser components to modify the light output of the components.  
           [0004]    One device which utilizes facet-coated laser components is the Optical Subassembly (OSA). The OSA includes an electrical circuit coupled to the laser component which causes the component to emit laser beams. The laser beams are directed toward a lens of the OSA which collimates the beams into an output beam or beams with a specified light output level. The facet coating of the different portions of the laser components serves to optimize the light output of the OSA.  
           [0005]    Since laser components are extremely small, they are typically held in a clamp or other securing mechanism during the facet coating process. Traditional clamps hold approximately twenty-eight (28) laser components each. The laser components are loaded into the clamp with spacers placed therebetween. Once the clamp is loaded with laser components, it is placed into a facet coating machine where portions of the components are coated with a facet coating substance, such as a light-reflective substance.  
           [0006]    [0006]FIGS. 1 and 2 show a conventional clamp  10  for use in a facet coating process. The clamp  10  includes a housing  20  into which a plurality of laser components  40 , in particular laser bars, are placed. The housing  20  includes a plurality of spacers  30  which are coupled to a spring-loaded mechanism (not shown) for holding the spacers together. The spacers  30  are disposed within a track  21  in the housing  20 , and are coupled to an end bar  31 , such that when the end bar is moved away from the spacers the spacers separate from one another. The spring-loaded mechanism causes the spacers  30  to come together again when the end bar  31  is released. The separation of spacers  30  from one another allows a user to insert laser components  40  into the housing  20  between the spacers. In particular, when the end bar  31  is retracted and the spacers  30  are separated from one another, a user may insert a laser component  40  so that upper  41  and lower  42  faces of the component are disposed against each of two spacers (see FIG. 2). Once components  40  have been placed in all the spaces between spacers  30 , the end bar  31  is released and the spring-loaded mechanism retracts to tightly hold the components between the spacers.  
           [0007]    [0007]FIG. 2 is a magnified view of the track  21  of the housing showing components  40  and spacers  30  placed therein. Note that a spacer  30  is disposed on either side of each component  40  to securely hold the component therebetween. The spacers  30  contact the upper  41  and lower  42  faces of the component  40 . The components includes test patterns  45  formed on the ends of the component. These test patterns  45  are areas of the laser component  40  which are not used, and thus they are eventually cut away in later stages of the manufacturing process.  
           [0008]    In order to perform the facet-coating process, the clamp  10  is loaded with components  40  at the points between the spacers  30  as described above. The clamp  110  is then placed in a facet coating device where the exposed side faces of the components are coated with a facet-coating substance. Once the facet coating is completed, the clamp  10  is removed from the facet coating device, and the components are removed therefrom.  
           [0009]    In order to remove the components  40 , the end bar  31  is moved away from the spacers, thereby causing the spacers to separate from one another. Then, the facet-coated components  40  are removed from the clamp  10  by hand.  
           [0010]    Since the spacers  30  essentially form a part of the housing  20 , they are reused each time each time a facet coating process is performed. Thus, the spacers often become worn or over-coated with a facet coating substance causing problems in subsequent processes. Additionally, the pressure of the spacers  30  against the upper and lower faces of the components  40  caused by the spring-loaded mechanism often causes cracking and chipping of the components.  
           [0011]    Thus, there is currently a need for an improved clamp for laser components.  
         SUMMARY OF THE INVENTION  
         [0012]    The present invention is a clamp for holding at least one electronic component. The clamp includes a first elongate member for contacting a first side of the electronic component(s) and a second elongate member for contacting a second opposing side of the electronic component(s). The clamp also includes at least one spacer abutting the electronic component(s). The first and second elongate members hold the electronic component(s) and the spacer therebetween.  
           [0013]    The above and other features of the present invention will be better understood from the following detailed description of the preferred embodiments of the invention which is provided in connection with the accompanying drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]    [0014]FIG. 1 is a top elevation view conventional clamp.  
         [0015]    [0015]FIG. 2 is a magnified view of a portion of the clamp of FIG. 1.  
         [0016]    [0016]FIG. 3( a ) is a top elevation view of a clamp according to an exemplary embodiment of the present invention.  
         [0017]    [0017]FIG. 3( b ) is a bottom elevation view of a clamp according to an exemplary embodiment of the present invention.  
         [0018]    [0018]FIG. 4 is a cross-sectional view of the clamp shown in FIG. 3( b ) taken along line  4 - 4 .  
         [0019]    [0019]FIG. 5 shows a magnified view of a portion of the clamp of FIG. 3( a ). 
     
    
     DETAILED DESCRIPTION  
       [0020]    Referring to FIGS.  3 ( a ),  3 ( b ) and  4 , there is shown a clamp  100  according to an exemplary embodiment of the present invention. FIGS.  3 ( a ) and  3 ( b ) show top and bottom elevation view, respectively of the clamp  100 , and FIG. 4 shows a cross-sectional view taken along line  4 - 4  in FIG. 3( a ). The clamp  100  is used to hold a plurality of laser components  140 , for example laser bars, and a plurality of spacers  130  during a facet-coating process.  
         [0021]    [0021]FIG. 3( a ) shows the clamp  100  which is formed by a substantially U-shaped housing  120 . The housing  120  includes an open end  101  through which laser components  140  and spacers  130  are inserted. The housing  120  may be formed of a unitary metal or plastic piece, however metal is preferred. The housing  120  includes a central portion  110  which serves to hold a plurality of spacers  130  and laser components  140 . The spacers  130  and laser components  140  are situated in the central portion  110  between first  180  and second  190  stoppers. The stoppers  180 ,  190  may also be formed of metal or plastic, but metal is preferred. The first stopper  180  includes a rear portion  181  which is coupled by a screw  182  to a first retaining foil  183 . The retaining foil  183  is formed of a flat, thin metal piece in the exemplary embodiment of the present invention, but may be formed from other materials without departing from the scope of the invention. A front portion  184  of the first stopper  180  is flattened to accept a few of the spacers  130  and laser components disposed in the central portion  110  of the housing  120  (see FIG. 3( b )). The dashed line in FIG. 3( a ) indicates the separation between the front  184  and rear  181  portions of the first stopper  180 . The retaining foil  183  of the first stopper  180  rests against a set of second retaining foils  150  disposed on the sides of the central portion  110  of the housing  120 . The first retaining foil  183  prevents random movements of the stopper  180  in the central portion  110  of the housing  120  due to orientation and handling, and allows the stopper to move transversely in the central portion. Again, the retaining foils  150  are formed of flat, thin metal pieces in the exemplary embodiment of the present invention, but may be formed from other materials without departing from the scope of the invention.  
         [0022]    The second stopper  190  is disposed at an opposite end of the central portion  110  from the first stopper  180 , at the other end of the plurality of spacers  130  and laser components  140 . The second stopper  190  includes a screw  191  which couples the stopper to a third retaining foil  192 . As with the first stopper  180 , the retaining foil  192  prevents the stopper  190  from falling through the central portion  110  of the housing and allows the stopper to move transversely in the central portion. The retaining foil  192  rests against a set of bars  123  which are coupled to the housing through screws  124 . The bars  123  may be formed of metal or any other suitable material known to those skilled in the art.  
         [0023]    The second retaining foil  150 , mentioned above, is sandwiched between the bars  123  and the housing  120  and is held thereby. The housing  120  also includes a bore  125  for receiving a screw  126 . When inserted in the bore  125  of the housing  120 , the screw  126  acts to press against the rear portion  181  of the first stopper  180 . Thus, when the screw  126  is rotated in a clockwise direction, the first stopper  180  is moved transversely in the central portion  110  of the housing  120  towards the second stopper  190 . The screw  126  is used for removing the components  140  and spacers  130  from the central portion  110  of the clamp as explained below.  
         [0024]    [0024]FIG. 3( b ) shows a bottom view of the clamp  100 . As explained above with reference to FIG. 3( a ), only a rear portion  181  of the first stopper  180  is shown in FIG. 3( b ) because the first few laser components  140  and spacers  130  rest on the front portion  184  of the first stopper. The housing  120  also includes first  127 , second  128  and third  129  tracks disposed therein. The first track  127  allows the second stopper  190  to move transversely therein.  
         [0025]    [0025]FIG. 4 shows a cross-sectional view of the clamp  100  taken along line  4 - 4  in FIG. 3( a ). As can be seen, the tracks  127 ,  128 , and  129  are disposed at different heights with respect to a bottom surface  111  of the housing  120 . The second stopper  190  is shown disposed in the first track  127 , and as stated above, the second stopper is movable transversely in the first track. As stated above, the third retaining foil  192  keeps the second stopper  190  disposed in the central portion  110  of the housing  120 . The third track  129  includes L-shaped portions  170  along the ends thereof closest to the central portion  110  of the housing  120 . The L-shaped portions  170 , along with the second retaining foils  150  operate to hold the laser components  140  and spacers  130  in the housing as explained below. FIG. 5 is a magnified view of the components  140  and spacers  130  as disposed within the central portion  110  of the housing  120 . Each laser component  140  is disposed between two spacers  130  as shown. The spacers  130  protect the upper and lower faces of the laser components  140  from damage during the facet-coating process. It should be noted that each laser component  140  includes a test pattern area  145  at opposite ends thereof, which is later removed when the laser component is diced. The test pattern areas  145  of the laser components  140  contacts the L-shaped portions  170  are held thereby. The bars  123 , which are held to the housing  120  by screws  124  (shown in FIGS.  3 ( a ) and  3 ( b )), sandwich the second retaining foils  150  therebetween. The retaining foils  150  prevent the laser components  140  and spacers  130  from falling out of the clamp  100  once they are placed therein.  
         [0026]    Laser components  140  and spacers  130  are loaded into the clamp  100  as described below. First, the second stopper  190  is removed from the clamp  100  by sliding it transversely out of the open end  101  of the housing  120  along first track  127 . Then, a first spacer  130  is loaded into the clamp  100  from the open end  101  of the housing  120 . The spacer  130  is placed into the L-shaped portions  170  of the third track  129  at the open end  101  of the housing  120 , and is moved down the track until it becomes disposed against the front portion  181  of the first stopper  180 . Next, a first laser component  140  is placed into the clamp  100  in the same manner in which the first spacer  130  was placed. This process is continued, alternating components  140  and spacers  130 , until the clamp  100  is fully loaded with spacers and components. Since the laser components  140  and spacers  130  are very small, the movement and placement of the components within the L-shaped portions  170  of the track  129  may be accomplished by a vacuum tool or other similar means.  
         [0027]    Once the clamp  100  is fully loaded with components, the second stopper  190  is placed back into the central portion  110  of the housing by sliding it into the open end  101  of the housing  120  on track  129 . The second stopper  190  is moved towards the last component  140  or spacer  130  in the clamp (preferably a spacer) until it abuts the last component or spacer. The second stopper  190  should be pressed against the last spacer  130  or component  140  until any spaces between the plurality of components and spacers have been substantially eliminated. Once the spaces have been substantially eliminated, the clamp  100  is ready for facet-coating. The entire clamp  100  is then placed into a facet-coating device (not shown) where the laser components  140  are coated on their exposed faces with, for example, a light reflective material.  
         [0028]    After the facet-coating, the clamp  100  is removed from the facet-coating device, and the laser components  140  and spacers  130  are removed from the clamp. The components  140  and spacers  130  are removed by first removing the second stopper  190 . Then, the screw  126  is rotated clockwise, by a screwdriver or other similar means, to move the first stopper  180  towards the plurality of spacers  130  and laser components  140 . The movement of the stopper  180  presses the spacers  130  and components  140  out of the open end  101  of the clamp  100 . After all the laser components  140  and spacers have been removed, the clamp is reloaded with more components and spacers, and the above process is repeated.  
         [0029]    It should be noted that since the spacers  130  do not form an integral part of the housing  120 , as opposed to the conventional clamp  10 , they may be removed and discarded after each facet-coating. Thus, the problems associated with conventional clamps, such as coating buildup on the spacers, are substantially eliminated. Additionally, since the screw  126  and first and second stoppers  180 ,  190  exert minimal pressure on the laser components  140  and spacers  130 , the cracking and breaking of components due to pressure is substantially decreased.  
         [0030]    Although the invention has been described in terms of an exemplary embodiment, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention.