CWDM Transceiver Active Alignment MEMS Mirror
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Solution Overview
Problem
The alignment of light sources with single mode fibers in CWDM transceiver modules is a complex and error-prone process due to the small core diameter of single mode fibers, leading to significant signal loss and increased manufacturing costs.
Innovation Solution
A CWDM transceiver module incorporating an integrated MEMS platform with an active alignment element, including a mirror array with gimbals that can rotate in two perpendicular directions, and a cap layer with reflector and filter coatings to precisely align light sources with single mode fibers, reducing alignment tolerances and simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional alignment methods are used to align light sources with single mode fibers, then alignment accuracy can be achieved, but the manufacturing process becomes complex and error-prone
Solution Approach 1:
The patent introduces an intermediary alignment structure consisting of a substrate with through-silicon vias (TSVs) and a cap layer with a V-groove. This intermediary structure provides mechanical support and precise positioning for the single mode fiber, acting as a mediator between the light source and the fiber. The V-groove in the cap layer mechanically couples the fiber with the substrate, establishing a stable and precise alignment relationship without requiring complex external alignment equipment or procedures.
2Reliability
If traditional alignment methods are used, then alignment can be performed, but signal loss increases due to manufacturing errors
Solution Approach 1:
The patent replaces complex mechanical alignment systems with a simplified mechanical coupling structure. The V-groove in the cap layer provides automatic mechanical positioning of the fiber, while reflector coatings on the cap layer surfaces optically guide and reflect light into the fiber core. This substitution of complex mechanical alignment with a combination of simple mechanical coupling and optical reflection reduces both the complexity and the signal loss associated with traditional alignment methods.
3Loss of energy
If tight alignment tolerances are required for single mode fiber coupling, then signal loss is reduced, but manufacturing difficulty increases
Solution Approach 1:
The patent changes the physical parameters of the alignment structure by creating a V-groove with specific geometric parameters in the cap layer. The V-groove dimensions and angle are optimized to automatically position the fiber at the correct location with appropriate alignment tolerance. Additionally, the reflector coating parameters (reflectivity, coverage area) are optimized to maximize light coupling into the fiber while maintaining ease of manufacturing through standard deposition processes.
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 active alignment system improves alignment accuracy, reduces signal loss, and simplifies the manufacturing process, enabling cost-effective batch production of CWDM transceiver modules with enhanced performance.
Implementation Method 1
The reflector coating pads may be deposited at a bottom surface of the cap layer and in between every two lenses sequentially and configured to totally reflect light in every wavelength
Implementation Method 2
The filter coating pads may be cascadly deposited in light path at a top surface of the cap layer and configured to be wavelength specific, transmitting light within one wavelength and reflecting light within other wavelength ranges
Implementation Method 3
a plurality of lenses disposed on the cap layer facing the light sources
Implementation Method 4
The active alignment element may include a mirror array. The mirror array includes a plurality of mirror structures, while each mirror structure includes a gimbal and a mirror plate
Data Source
AI summary
A CWDM transceiver module includes: a substrate; a plurality of light sources disposed on the substrate; a spacer layer disposed above the substrate, a cavity being defined in the space layer to accommodate the light sources; a cap layer transparent to light emitted from the light sources and disposed on the spacer layer, a notch for assembling a waveguide being formed in the cap layer; a plurality of lenses disposed on the cap layer facing the light sources; reflector coating and filter coating disposed on surfaces of the cap layer; an active alignment element disposed on the cap layer; and a reflector disposed at bottom of the notch.