Compact Optical Module for Endoscopes Using Substrate Integration
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Solution Overview
Problem
There is a challenge in reducing the diameter and length of optical modules, particularly those used in endoscopes, while maintaining high transmission efficiency and reliability for optical signal transmission.
Innovation Solution
The optical module design includes a VCSEL optical element, a ferrule holding optical fiber, and a configuration of substrates and side surface substrates with electrodes, allowing for compact integration with signal cables and efficient optical signal transmission, using ceramic substrates and resin for stability and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If optical signal transmission via optical fiber is used instead of electric signal transmission via metal wire, then transmission efficiency and reliability are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent integrates the optical element, optical fiber, signal cable, and electrical connection into a single unified module structure. The optical element is mounted on the substrate with the optical fiber positioned directly against its light-emitting or light-receiving surface, while signal cables are bonded to electrodes on the same substrate, combining optical and electrical functions in one compact unit.
Solution Approach 2:
The substrate serves multiple functions simultaneously: it mounts the optical element, positions the optical fiber, provides electrical connection through electrodes, and bonds signal cables. This multi-functional design reduces the need for separate components and simplifies the overall module structure while maintaining high transmission efficiency.
2Ease of operation
If compact integration is achieved to reduce diameter and length, then ease of operation and minimal invasiveness are improved, but manufacturing precision requirements increase
Solution Approach 1:
The optical fiber is positioned in advance against the light-emitting or light-receiving surface of the optical element during module assembly. The substrate is designed with predetermined positions for the optical element, optical fiber, and electrodes, allowing components to be integrated in a fixed sequence without requiring complex real-time alignment adjustments during manufacturing.
Solution Approach 2:
The substrate acts as an intermediary platform that pre-establishes the spatial relationships between the optical element, optical fiber, and signal cables. By bonding these components to the substrate at predetermined locations, the module achieves compact integration while reducing the precision requirements for final assembly, as the substrate itself provides the alignment framework.
3Device complexity
If multiple components are integrated on a single substrate, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The module is segmented into distinct functional zones on the substrate: the optical element mounting area, the optical fiber positioning area, and the signal cable bonding area with electrodes. This segmentation allows each component to be placed and bonded independently at its designated location, simplifying the manufacturing process while maintaining precise spatial relationships between components.
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 design results in a compact, high-efficiency optical module with reduced noise susceptibility and ease of manufacturing, suitable for endoscopic applications with minimal invasiveness and high reliability.
Implementation Method 1
an optical element including a light emitting section or a light receiving section
Implementation Method 2
an optical element including a light emitting section or a light receiving section
Implementation Method 3
an optical fiber for transmitting the optical signal
Implementation Method 4
a signal cable for transmitting an electric signal, a distal end portion of which is bonded to the electrode of the side surface substrate
Data Source
AI summary
An optical module includes an optical element, a first substrate, on a first principal plane of which the optical element is mounted, a holding member disposed on a second principal plane of the first substrate, an optical fiber inserted into a through hole of the holding member, a holding substrate with an opening, a wall surface of which is in contact with an outer peripheral surface of the holding member, an interconnecting substrate connecting the first substrate and the holding substrate, a side surface substrate, an end portion of which is connected to the holding substrate and on which an electrode is disposed, and a signal cable, a distal end portion of which is bonded to the electrode of the side surface substrate.