Ablation Carrier for Optical Fiber and Die Alignment
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Solution Overview
Problem
The existing methods for manufacturing precision optical links between optical components, such as optical fibers and dies, are costly and not scalable for mass production, requiring complex alignment and additional optical components like mirrors and lenses to redirect light.
Innovation Solution
A carrier part with alternating layers of materials susceptible and insusceptible to ablation is used to create geometric features for precise mounting of optical components, allowing for in-line alignment and butt coupling without additional optical components, and incorporating electrical tracks and thermal conductivity for improved signal integrity and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional coupling schemes with mirrors and lenses are used to redirect light, then the optical link can be established between fiber and die, but absorption and reflection losses occur and device complexity increases
Solution Approach 1:
The patent extracts and eliminates the mirror and lens components from the optical coupling system. By using a perpendicular mounting arrangement where the optical die is mounted with its active layer parallel to the carrier, the light path becomes direct from fiber to die without requiring intermediate optical components for redirection, thereby removing the sources of absorption and reflection losses.
Solution Approach 2:
The patent inverts the conventional mounting arrangement. Instead of mounting the optical die with its active layer perpendicular to the carrier (which requires mirrors to redirect light), the die is mounted with its active layer parallel to the carrier surface, allowing direct optical coupling with the fiber and eliminating the need for light redirection components.
2Manufacturing precision
If precise alignment of optical fiber and die is achieved using conventional methods, then optical link is established, but manufacturing cost increases and mass production scalability decreases
Solution Approach 1:
The carrier serves multiple functions simultaneously: it provides mechanical support for both the optical fiber and optical die, establishes precise alignment through its geometric features, enables direct optical coupling, and eliminates the need for separate mirror and lens components. This multi-functionality simplifies the manufacturing process and reduces costs while maintaining alignment precision.
Solution Approach 2:
The patent segments the optical coupling function into distinct geometric features on the carrier: a fiber mounting feature for securing the fiber, a die mounting feature for positioning the optical die, and alignment features that ensure precise registration. This segmentation allows each feature to be optimized independently while working together to achieve precise alignment at low cost.
3Reliability
If optical die is mounted perpendicular to carrier with mirror for light redirection, then optical link is established, but additional optical components are required increasing device complexity
Solution Approach 1:
The patent merges the fiber mounting, die mounting, and alignment functions into a single carrier structure. The carrier integrates geometric features that simultaneously secure the fiber, position the die, and ensure precise alignment between them, eliminating the need for separate mirror and lens components while maintaining reliable optical coupling.
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 approach enables cost-effective, mass-producible optical engines with reduced absorption and reflection losses, improved signal integrity, and simplified thermal management, eliminating the need for expensive thermal bridges and additional optical components.
Implementation Method 1
a plurality of features is generated, wherein each of the generated features provides a respective mounting for each of the at least two optical elements
Data Source
AI summary
A low-cost and mass producible carrier part for precise mounting of optical components such as an optical fiber and optical die and associated fabrication process.