Lens-Type Optical Fiber Array Stacking for Passive Focal Alignment
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Solution Overview
Problem
Current optical fiber array stacking technologies require expensive molds for alignment, leading to high manufacturing costs and low yield due to the lack of a convenient method to confirm correct focal length positioning.
Innovation Solution
A lens-type optical fiber array stacking structure utilizing slide rails, protruding ribs, and passive alignment parts for automatic alignment and positioning of optical fiber array modules and lens groups at the correct focal length, reducing the need for external molds and improving yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If external molds are used to align lens groups with optical fibers, then alignment precision is improved, but manufacturing cost increases
Solution Approach 1:
The optical fiber array module is designed with self-aligning features including a protruding rib that fits into a groove on the lens group, and a positioning hole that receives a positioning pin. This self-service alignment mechanism eliminates the need for expensive external molds while maintaining precise alignment between the optical fibers and lens groups.
Solution Approach 2:
The alignment features (protruding rib, groove, positioning hole, and positioning pin) are pre-integrated into the module structure during manufacturing. This preliminary action ensures that when assembly occurs, the components are already configured to align automatically without requiring additional alignment tools or processes.
2Manufacturing precision
If external molds are used for alignment, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The module incorporates self-aligning structural features directly into its design: a protruding rib on the module body fits into a corresponding groove on the lens group, and a positioning hole receives a positioning pin. This self-service mechanism achieves accurate positioning without requiring complex external molds or alignment devices.
Solution Approach 2:
The alignment and positioning functions are merged into the module's own structure rather than being separate external components. The protruding rib, groove, positioning hole, and positioning pin are integrated features that work together as a unified alignment system, reducing overall device complexity.
3Manufacturing precision
If traditional alignment methods are used, then focal length positioning is achieved, but yield decreases due to lack of verification
Solution Approach 1:
The patent implements a verification mechanism where the positioning hole and positioning pin provide immediate feedback on alignment status. The positioning pin must precisely fit into the positioning hole, providing tactile and visual confirmation that the module is correctly positioned at the focal length, thereby enabling quality verification during assembly and improving yield.
Data Source
AI summary
The present invention relates to a lens-type optical fiber array stacking structure. Through the arrangement of two guide pins corresponding to the protruding ribs of the optical fiber array module, the arrangement of the concave-convex matching between the first passive alignment part and the second passive alignment part of two optical fiber array modules, the arrangement of the first supporting part of the docking end lens group and the first lens supporting platform of the substrate, and/or the arrangement of the second supporting part of the chip end lens group and the second lens supporting platform of the substrate, the optical fiber array module and each lens group can be passively positioned at the correct focal length during assembly, thereby improving yield and reducing costs.