Hermetically-Sealed Light Engine with External AWG
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Solution Overview
Problem
The challenge in optical transceiver manufacturing lies in achieving higher speeds and lower costs while managing thermal complexity and insertion loss, particularly in hermetically-sealed transmitter optical subassemblies (TOSAs) that require arrayed waveguide gratings and temperature control devices, which increase manufacturing complexity and cost.
Innovation Solution
A TOSA design with a hermetically-sealed light engine housing and an arrayed waveguide grating disposed externally, optically coupled via an optical receptacle, allowing for a smaller cavity size and reduced component count within the housing, thereby minimizing manufacturing complexity and cost while maintaining thermal management efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If arrayed waveguide grating and temperature control devices are included within the hermetically-sealed housing, then optical performance and thermal management are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent divides the hermetically-sealed housing into two distinct sections: a compact sealed cavity containing only the laser arrangement, and an external unsealed region housing the arrayed waveguide grating and temperature control devices. This segmentation allows the critical optical components to remain protected while simplifying manufacturing of the sealed portion.
Solution Approach 2:
The arrayed waveguide grating and temperature control devices are extracted from the hermetically-sealed housing and positioned externally. This extraction reduces the complexity of the sealed cavity, enabling simpler manufacturing processes while maintaining optical performance through preserved optical coupling.
2Reliability
If arrayed waveguide grating and temperature control devices are included within the hermetically-sealed housing, then optical performance and thermal management are improved, but manufacturing cost increases
Solution Approach 1:
The housing is segmented into a simple sealed cavity and an external component region, reducing the complexity and cost of hermetic sealing operations while maintaining optical performance through the optical coupling interface between the two sections.
Solution Approach 2:
By extracting the arrayed waveguide grating and temperature control devices from the sealed housing, the patent reduces the number of components requiring precision placement and sealing, thereby lowering manufacturing costs while preserving optical functionality.
3Reliability
If hermetically-sealed housing includes all components, then optical performance is maintained, but thermal management complexity increases
Solution Approach 1:
The patent segments the thermal management system into a simplified sealed portion with reduced thermal control requirements and an external region where temperature control devices can operate without compromising the hermetic seal, thereby reducing overall thermal management complexity.
Solution Approach 2:
Temperature control devices are extracted from the hermetically-sealed cavity and positioned externally, where they can manage heat dissipation without interfering with the sealed environment, simplifying both thermal management and manufacturing 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
This design enables efficient thermal management and reduced power consumption, achieving higher transmission rates and distances with lower manufacturing costs by externalizing the arrayed waveguide grating and associated components, thus simplifying the hermetically-sealed package and enhancing serviceability.
Implementation Method 1
The hermetically-sealed light engine includes a housing defined by a plurality of sidewalls. The housing defines a cavity that is hermetically-sealed to prevent introduction of contaminants that would otherwise reduce power.
Implementation Method 2
The hermetically-sealed light engine optically couples to an external AWG by way of an optical receptacle.
Data Source
AI summary
In general, a TOSA consistent with the present disclosure includes a light driving circuit coupled to a hermetically-sealed light engine. The hermetically-sealed light engine includes a housing defined by a plurality of sidewalls. The housing defines a cavity that is hermetically-sealed to prevent introduction of contaminants that would otherwise reduce optical power. The hermetically-sealed light engine optically couples to an external arrayed waveguide grating (AWG), or other multiplexing device, by way of an optical receptacle. The optical receptacle can include a waveguide implemented external to the hermetically-sealed cavity and can include, for instance, an optical isolator, fiber stub, and fiber ferrule section. Thus, the external AWG and associated external optical coupling components advantageously allow for the hermetically-sealed light engine to have a cavity with dimensions relatively smaller than other approaches that dispose an AWG and associated components within a hermetically-sealed cavity.