Optical Engine Module Layout for Compact Low-Loss Fiber Coupling

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Solution Overview

Problem

Existing optical systems face challenges in efficiently manipulating and directing optical signals with minimal signal loss, particularly in compact designs that require precise alignment and dynamic control of optical components.

Innovation Solution

The development of an optical engine module comprising a backplate, fiber array unit, optical engine die, and socket, which includes optical components like lenses, mirrors, and filters, along with control electronics for precise alignment and efficient light manipulation, and a fiber array unit with actuators for dynamic control of optical signals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If compact design is implemented, then device size is reduced, but alignment precision deteriorates

Engineering Contradiction:

Improvedevice sizeVSAvoidalignment precision

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The optical engine module is divided into separate functional components including fiber array units, optical engine die, and socket assembly, each manufactured and aligned independently before final integration. This segmentation allows for precise alignment of each component without requiring the entire system to be manufactured in one precision operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The socket assembly serves as an intermediary component that provides precise mechanical alignment between the fiber array units and the optical engine die. The socket includes alignment features such as guide pins and precision-machined receptacles that maintain accurate positioning despite the compact overall device size.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of energy

If precise alignment is achieved, then signal loss is minimized, but device complexity increases

Engineering Contradiction:

Improvesignal lossVSAvoiddevice complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

Multiple alignment and coupling functions are merged into integrated components. The socket assembly combines mechanical support, alignment features, and electrical connections in a single component. The fiber array units integrate multiple optical fibers with common alignment references, reducing the number of separate alignment operations required.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The optical engine module incorporates self-aligning features such as tapered ferrules, guide pins, and precision-machined receptacles that automatically establish correct alignment during assembly. The design includes self-adjusting mechanisms that compensate for minor manufacturing tolerances without requiring complex external alignment equipment or procedures.

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If dynamic control is added, then optical signal manipulation is improved, but device complexity increases

Engineering Contradiction:

Improveoptical signal manipulationVSAvoiddevice complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The optical engine module incorporates dynamic control capabilities through integrated actuators and control electronics that can adjust optical component positions and orientations in real-time. This allows the system to adapt to different operational requirements while maintaining a relatively simple overall structure through modular design.

Inventive Principle:

Principle #15Dynamics

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 optical engine module achieves efficient light transfer with minimal loss by ensuring precise alignment and dynamic control of optical signals, suitable for applications in imaging systems, displays, optical communication, and sensors.

Implementation Method 1

The OE may include a combination of optical elements such as lenses, mirrors, and prisms, arranged to efficiently couple light between various optical fibers and other optical components

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 2

The OE may include a combination of optical elements such as lenses, mirrors, and prisms, arranged to efficiently couple light between various optical fibers and other optical components

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 3

The role of the OE may include aligning and focusing the light beams to maximize the efficiency of the light transfer

Methodology Applied

Scientific EffectFocusing: Focusing

Data Source

PatentUS20250389915A1Optical engine module with fiber array unit and methods for forming the same

Publication Date: 2025.12.25 TAIWAN SEMICONDUCTOR MANUFACTURING CO LTD

AI summary

An optical engine module may include a backplate, a fiber array unit attached to the backplate, an optical engine die attached to the backplate adjacent the fiber array unit; and a socket attached to the backplate and connected to the optical engine die. A method of forming an optical engine module may include attaching a fiber array unit to a backplate, attaching an optical engine die to the backplate adjacent the fiber array unit, and attaching the backplate to a socket such that the fiber array unit and the optical engine die are between the backplate and the socket.