Hybrid Optical Coupling Module Alignment and Manufacturing
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Solution Overview
Problem
Existing hybrid optical coupling modules face challenges in mass productivity due to the difficulty in simultaneously manufacturing optical and electrical components on a single substrate, leading to high defective rates and increased production costs, especially when defects occur in multi-channel systems.
Innovation Solution
A hybrid optical coupling module is designed where the optical unit with an array lens and the electrical unit with a photo diode and transimpedance amplifier are independently manufactured and tested, allowing for active alignment, reducing defective rates and enabling the discarding of only the defective unit, while the array lens is bonded to the optical transmission means for improved light focusing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If optical and electrical components are manufactured on a single substrate using hybrid integration, then integration is achieved, but manufacturing complexity increases and productivity decreases
Solution Approach 1:
The module is divided into separate optical and electrical units that are manufactured independently on different substrates. The optical unit is fabricated on an optical substrate while the electrical unit is fabricated on an electrical substrate, allowing parallel manufacturing processes and improving mass productivity while maintaining integration functionality through subsequent coupling.
2Reliability
If all components are assembled before testing, then complete system testing is possible, but defective components cannot be identified individually increasing waste
Solution Approach 1:
Testing is performed on the optical unit and electrical unit separately before they are coupled together. This preliminary testing allows defective units to be identified and discarded individually before final assembly, preventing waste of good components and reducing overall manufacturing loss while ensuring system reliability through pre-validated units.
3Device complexity
If a 90° reflection coupling method is used, then coupling structure is simple, but coupling efficiency degrades with increased distance between components
Solution Approach 1:
A lens array is introduced as an intermediary component between the optical unit and electrical unit to focus and guide optical signals. This mediator enables efficient optical coupling over longer distances by concentrating light paths, reducing signal loss while maintaining a relatively simple overall coupling structure through the use of standard lens array technology.
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 approach reduces defective rates and production costs by allowing independent testing and alignment of optical and electrical units, facilitating efficient light focusing and reducing loss rates, thus enhancing the manufacturing efficiency and productivity of hybrid optical coupling modules.
Implementation Method 1
an array lens that is bonded at a point where the optical signal of the optical transmission means is output and focuses the output optical signal
Implementation Method 2
an electrical unit configured to receive the optical signal focused through the array lens and convert the received optical signal into an electrical signal
Data Source
AI summary
Provided are a hybrid optical coupling module and a manufacturing method thereof.The hybrid optical coupling module includes an optical unit configured to include an optical transmission means that transmits an optical signal, and an array lens that is bonded at a point where the optical signal of the optical transmission means is output and focuses the output optical signal, and an electrical unit configured to receive the optical signal focused through the array lens and convert the received optical signal into an electrical signal. Here, an alignment mark is formed on the optical transmission means and the array lens so that the array lens is bonded at the point where the optical signal of the optical transmission means is output.