Opto-Electric Hybrid Module Waveguide Alignment
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Solution Overview
Problem
The existing opto-electric hybrid modules experience increased propagation loss due to light beam diffusion and thermal stress-induced distortion of the optical waveguide during the mounting process, which affects the alignment accuracy of light-emitting and light-receiving elements with the optical path conversion mirrors.
Innovation Solution
The opto-electric hybrid module design incorporates an optical waveguide with a core extension that positions the distal end surface in face-to-face relationship with the optical elements, reducing the distance between the elements and the optical path conversion mirrors, and bonding the optical waveguide to the electric circuit board after optical element mounting, thus minimizing thermal stress on the waveguide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the optical waveguide is bonded to the electric circuit board before mounting optical elements, then the manufacturing process is simplified, but thermal stress during mounting causes distortion of the optical waveguide and misalignment
Solution Approach 1:
The optical waveguide is pre-positioned and fixed to the electric circuit board at predetermined locations before the optical elements are mounted. This preliminary positioning ensures that the waveguide maintains correct alignment with the optical elements during subsequent mounting processes, while the bonding is completed after mounting to avoid thermal stress distortion
2Ease of operation
If the distance between optical elements and optical path conversion mirrors is increased, then the mounting process becomes easier, but light beam diffusion increases and propagation loss increases
Solution Approach 1:
The optical waveguide structure is designed with different regional characteristics: the region near the optical elements has a smaller core diameter to reduce light beam diffusion and propagation loss, while other regions may have different dimensions optimized for their specific functions. This local differentiation allows short distance mounting for low loss while maintaining manufacturability
3Ease of operation
If the core diameter of the optical waveguide is increased, then light propagation is easier, but light beam diffusion increases and propagation loss increases
Solution Approach 1:
The optical waveguide employs a non-uniform core diameter design where the core is smaller in regions close to optical elements to minimize diffusion and propagation loss, while having larger dimensions in other regions to facilitate light propagation and ease of operation
Solution Approach 2:
The patent introduces positional dimension as a critical parameter, differentiating the waveguide structure by location relative to optical elements. The core diameter varies along the length of the waveguide, creating a gradient structure that optimizes both propagation ease and loss reduction in different spatial regions
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 enhances the reliability of light propagation and reduces propagation loss by ensuring precise alignment and minimizing thermal stress on the optical waveguide, resulting in improved light beam guidance and reduced diffusion.
Implementation Method 1
said core including an end portion formed with a reflection portion for reflecting light beams to allow the light beams to propagate between said core and said optical element
Data Source
AI summary
An opto-electric hybrid module capable of reducing the propagation loss of light beams, and a manufacturing method thereof. An opto-electric hybrid module in which a light-emitting element and a light-receiving element are mounted on the front surface side of an electric circuit board E, and an optical waveguide W1 is bonded to the back surface side thereof. The optical waveguide W1 includes a core having opposite end portions formed as light reflection portions. Portions of the core near the opposite end portions are formed as extensions extending from the light reflection portions toward the light-emitting element and the light-receiving element. The extensions and are positioned in through holes for light propagation formed in the electric circuit board E, and have distal end surfaces and in face-to-face relationship with a light-emitting portion of the light-emitting element and a light-receiving portion of the light-receiving element, respectively.