Electrical Connector Turn for Parallel VCSEL Optical Coupling
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Solution Overview
Problem
Current packaging solutions for surface emitting lasers in consumer electronics require expensive and complex 90-degree light-pipe designs with high precision alignment, which are costly and difficult to implement in small form factor devices.
Innovation Solution
The solution involves forming an electrical connector on a printed circuit board substrate to create a turn that replaces the optical path turn, allowing for optoelectronic devices to be coupled parallel to the mounting board, eliminating the need for a 90-degree light-pipe and using a fiber butt-coupling method for alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a 90-degree light-pipe with ray optic lens system is used to integrate SE laser device into thin mobile device package, then light coupling to fiber is achieved, but manufacturing cost increases and device complexity increases
Solution Approach 1:
The patent extracts the complex ray optic lens system and 90-degree light-pipe from the optical path, replacing them with a simplified direct coupling approach where the VCSEL array emits light parallel to the mounting board and couples directly to fibers without requiring angular redirection components
Solution Approach 2:
Instead of bending the light path at 90 degrees through prisms and lenses as in conventional designs, the patent inverts the approach by having the VCSEL arrays emit light parallel to the board surface and using the electrical connector's physical turn to achieve the spatial redirection, thereby simplifying the optical system
2Shape
If a 90-degree light-pipe with ray optic lens system is used for SE laser device integration, then optical path bending is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The patent removes the precision-critical optical components (prisms, lenses, light-pipes) that require high alignment precision, replacing them with a mechanical turn in the electrical connector that provides spatial redirection without stringent alignment requirements
Solution Approach 2:
The patent employs standard electrical connectors with inherent turns as off-the-shelf components rather than custom-machined optical components, significantly reducing manufacturing precision requirements and enabling cost-effective production
3Reliability
If an expensive ray optic lens system is used for SE laser device packaging, then light coupling to fiber is achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive ray optic lens systems with standard electrical connectors that have inherent turns, using readily available, low-cost components to achieve the same spatial redirection function, thereby dramatically reducing manufacturing costs
Solution Approach 2:
The electrical connector serves dual functions: providing electrical connection to the VCSEL arrays and simultaneously providing the spatial turn for optical path configuration, eliminating the need for separate, expensive optical redirection components
4Shape
If conventional packaging with 90-degree light-pipe is used, then light direction change is achieved, but overall package size increases
Solution Approach 1:
The patent merges the electrical connection function and the optical path redirection function into a single component (the electrical connector with turn), eliminating the need for separate light-pipe and lens assemblies, thereby reducing the overall package footprint
Data Source
AI summary
Exemplary embodiments of methods and apparatuses to provide an electro-optical alignment are described. An electrical connector is formed on a printed circuit board substrate that extends onto a side surface of the substrate to form an electrical turn. An optoelectronic die is placed onto the printed circuit board substrate. The optoelectronic die on the printed circuit board substrate is erected over a mounting board to provide optical coupling substantially parallel to the mounting board.