Optical Fiber Fixation Structure Resin Detachment
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Solution Overview
Problem
Conventional optical fiber fixation structures in semiconductor laser modules have low reliability due to resin coming off under tensile stress, leading to positional misalignment, and existing solutions complicate manufacturing with grooved pedestals and increased costs.
Innovation Solution
An optical fiber fixation structure featuring a protuberance on the base plate with resin covering side surfaces, preventing resin detachment and misalignment, and a method involving a two-stage resin application process to securely fix the optical fiber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If resin is applied only on the upper surface of the fiber mount to fix the optical fiber, then the fixing structure is simple, but the resin comes off under tensile stress causing positional misalignment
Solution Approach 1:
The resin application is extended from a two-dimensional surface (upper surface only) to a three-dimensional configuration that covers the side surfaces of the protuberance. This dimensional extension creates a multi-surface bonding interface that prevents resin detachment under tensile stress while maintaining structural simplicity.
Solution Approach 2:
The fixing structure utilizes a composite configuration where the resin forms a multi-layered bonding interface across different surfaces (upper surface and side surfaces) of the protuberance. This composite approach distributes stress across multiple bonding zones, enhancing fixation reliability without complicating the overall structure.
2Reliability
If a groove is formed in the fiber fixing pedestal to prevent resin detachment, then resin detachment is reduced, but the structure becomes complicated and manufacturing cost increases
Solution Approach 1:
Instead of modifying the fiber fixing pedestal by adding a groove (complexifying the pedestal structure), the invention inverts the approach by modifying the resin application pattern. The resin is applied on the side surfaces of an existing protuberance, achieving the same reliability benefit without altering the fundamental pedestal structure.
Solution Approach 2:
The groove feature is extracted from the pedestal structure and replaced by a resin application pattern on the protuberance side surfaces. This extraction eliminates the need for complex pedestal machining while maintaining the stress-distribution function that prevents resin detachment.
3Reliability
If a groove is formed in the fiber fixing pedestal to accommodate adhesive, then spaces are provided for thermal expansion relief, but the manufacturing process becomes cumbersome due to alignment requirements
Solution Approach 1:
Rather than forming a groove in the pedestal and requiring precise alignment with the optical axis, the invention applies resin on the side surfaces of a protuberance. This inverted approach provides thermal expansion relief through the same multi-surface bonding interface without requiring complex alignment during manufacturing.
4Ease of manufacture
If resin covers only the upper surface of the fiber mount, then the manufacturing process is simple, but the resin detaches when tensile stress is applied
Solution Approach 1:
The resin application extends from a single upper surface to multiple surfaces including side surfaces of the protuberance. This dimensional expansion creates additional bonding interfaces that distribute tensile stress, significantly enhancing bonding strength while maintaining manufacturing simplicity through a straightforward resin coating process.
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 structure ensures high reliability by preventing resin detachment and minimizing positional misalignment, while simplifying the manufacturing process and reducing costs.
Implementation Method 1
a resin that fixes both of the optical fiber and a covering material on the protuberance
Data Source
AI summary
The present invention provides a semiconductor laser module with high reliability that has a simple structure that can prevent a resin for fixing an optical fiber from coming off. The semiconductor laser module 1 has a base plate 11, a semiconductor laser device 22 disposed on the base plate 11, an optical fiber 30 operable to transmit a laser beam emitted from the semiconductor laser device 22, a fiber mount 40 that projects from an upper surface 11A of the base plate 11, and a resin 50 for fixing the optical fiber 30 on the fiber mount 40. The resin 50 is formed so as to cover side surfaces 42A, 42B, 43A, and 43B of the fiber mount 40.