Cylindrical Aligner for Lens Opto-Electronic Precision
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Solution Overview
Problem
The existing methods for aligning lenses with opto-electronic devices in optical communication systems, such as passive and active alignment using X-Y precision aligners, are slow and costly, resulting in low manufacturing output and high costs per transceiver module.
Innovation Solution
An aligner device with a cylindrical body and coaxial openings is used, featuring a base with opto-electronic device openings that provide a snug fit for precise alignment and retention, along with an outer ring for mating optical devices, allowing for efficient alignment and mounting on a substrate like a printed circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If passive alignment or active alignment using X-Y precision aligners is used, then lens alignment with opto-electronic devices is achieved, but manufacturing output is low and manufacturing cost is high
Solution Approach 1:
The alignment system is segmented into a reference structure with precision-machined openings and a separate aligner device with corresponding alignment features. This segmentation allows the reference structure to be manufactured once with high precision, while the aligner device can be rapidly reproduced and used for multiple alignment operations, thereby improving productivity without sacrificing alignment precision.
Solution Approach 2:
The aligner device incorporates self-aligning features where the alignment surfaces and openings automatically guide the lens and opto-electronic device into precise alignment through mechanical constraints. This self-service alignment mechanism eliminates the need for slow manual or robotic adjustment processes, significantly increasing manufacturing output while maintaining high alignment precision.
2Manufacturing precision
If passive alignment or active alignment using X-Y precision aligners is used, then lens alignment with opto-electronic devices is achieved, but manufacturing cost is high
Solution Approach 1:
The reference structure is manufactured in advance with precision-machined openings and alignment features that encode the exact positional relationships needed for alignment. This preliminary action transfers the complexity and cost of high-precision manufacturing to a single reference component, while subsequent aligner devices and assembly operations become simpler and less costly, reducing overall manufacturing cost while maintaining alignment precision.
Solution Approach 2:
The alignment geometry is copied from the master reference structure to multiple aligner devices through precision machining or molding. This copying process allows the expensive precision alignment geometry to be replicated across many aligner devices at low marginal cost, making high-precision alignment accessible for mass production without proportionally high manufacturing costs.
3Manufacturing precision
If traditional alignment methods are used, then alignment is achieved, but alignment speed is slow
Solution Approach 1:
The invention replaces slow mechanical adjustment systems (X-Y precision aligners with manual or robotic control) with a mechanical constraint system based on precision-machined geometric features. The alignment is achieved through the physical constraints of the reference structure and aligner device geometry, which automatically establish precise positions without requiring slow iterative mechanical adjustments, thereby dramatically increasing alignment speed while maintaining precision.
Data Source
AI summary
Alignment of one or more lenses with one or more opto-electronic devices in an opto-electronic system is aided by an aligner device having a substantially cylindrical body with a base and an outer ring. The base has one or more openings, one of which is a first opto-electronic device opening. The first opto-electronic device opening has a substantially circular shape coaxial with the outer ring and coaxial with a central axis of the aligner device.