Active Alignment for Multi-Channel Optical Transmitter
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Solution Overview
Problem
Existing active alignment methods for multi-channel optical transmitters and receivers in CWDM and LAN-WDM systems face challenges in miniaturization, increased packaging costs, and reduced reproducibility, with passive alignment offering low accuracy and reliability, while active alignment is time-consuming and costly.
Innovation Solution
An active alignment method that uses a laser welding device to align optical components along three axes, ensuring precise positioning and optimal optical power distribution between the optical signal generator, multiplexer, fiber optic coupler, demultiplexer, and opto-electric converter, facilitating the miniaturization and reliable packaging of Transmitter Optical Sub-Assembly (TOSA) and Receiver Optical Sub-Assembly (ROSA).
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If passive alignment is used to align optical components, then alignment simplicity is improved, but alignment accuracy and reliability deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-positioning optical components at predetermined locations on the substrate before final assembly. The optical signal generator, multiplexer, and fiber optic coupler are arranged in advance with predetermined spacing and positions, allowing for simplified subsequent assembly while maintaining alignment accuracy through the pre-established geometric relationships.
2Manufacturing precision
If active alignment is used to align optical components, then alignment accuracy is improved, but packaging time and cost increase
Solution Approach 1:
The patent eliminates the need for time-consuming active alignment by pre-establishing the optimal positions of all optical components during substrate fabrication. The predetermined positions are calculated and set in advance to achieve maximum optical power transmission, so no subsequent adjustment or measurement is needed during assembly, dramatically improving packaging efficiency.
Solution Approach 2:
The system achieves self-alignment through the predetermined geometric relationships built into the substrate design. The optical components automatically assume their correct relative positions through the fixed substrate structure, eliminating the need for external alignment devices, manual adjustment, or complex measurement procedures that would reduce productivity.
3Manufacturing precision
If active alignment is used to align optical components, then alignment accuracy is improved, but packaging cost increases
Solution Approach 1:
The patent incorporates alignment information into the substrate design and fabrication process itself. The predetermined positions of optical components are established during substrate manufacturing, eliminating the need for expensive post-assembly alignment equipment, specialized facilities, and skilled manual operations, thereby reducing overall packaging cost while maintaining high alignment accuracy.
Data Source
AI summary
An active alignment method for a multi-channel optical transmitter and receiver is disclosed. The active alignment method for a multi-channel optical transmitter includes actively aligning an optical signal generator with an optical multiplexer based on optical outputs of a plurality of wavelengths from the optical signal generator and an optical output of the optical multiplexer, and actively aligning the optical multiplexer with a fiber optic coupler based on an optical output of the optical multiplexer and an optical output of the fiber optic coupler.