Laser Diode Adapter for Stress-Free PCB Connection
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Solution Overview
Problem
Traditional methods for connecting laser diodes to circuit boards, such as bending and soldering, cause stress and reduce the mean time between failures, require complex labor, and can negatively impact radio frequency performance due to the need for long legs and sharp bends in optical fiber cables.
Innovation Solution
A laser diode adapter with conductive pads that span the distance between the diode's legs, allowing for electrical connection without deforming the legs and avoiding sharp bends in optical fiber cables by coupling directly to the circuit board's surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the legs of the laser diode are bent and soldered to the PCB, then the laser diode can be electrically connected to the circuit board, but stress is caused in the enclosure (cracking in glass feed-through) and mean time between failures is reduced
Solution Approach 1:
A support structure (intermediary component) is introduced between the laser diode and the PCB. This support structure has a first surface that contacts the bottom of the laser diode enclosure and a second surface that contacts the PCB, providing mechanical support without requiring bending of the laser diode legs. This eliminates stress on the glass feed-through and improves reliability.
Solution Approach 2:
The support structure extends in a vertical dimension perpendicular to the PCB surface, allowing the laser diode to be positioned at an elevated location rather than being directly soldered to the PCB plane. This dimensional change enables electrical connection without mechanical deformation of the legs.
2Reliability
If the legs are bent to be soldered in the same plane, then electrical connection is achieved, but the legs must be relatively long which negatively impacts radio frequency performance and bandwidth
Solution Approach 1:
The support structure serves as an intermediary that provides electrical connection pathways without requiring long leg extensions. The support structure can incorporate conductive elements or traces that provide the necessary electrical pathways, allowing the laser diode legs to remain short while achieving proper RF performance.
3Ease of operation
If a multilayer PCB with protruding portion is used to avoid bending legs, then electrical connection without deformation is achieved, but complex manufacturing is required including forming separate upper and lower portions that are interconnected and laminated
Solution Approach 1:
The connection system is segmented into separate functional components: a standard PCB and a separate support structure. This segmentation allows each component to be manufactured using conventional, simpler processes rather than requiring complex multilayer PCB fabrication with protruding portions and interconnections.
Solution Approach 2:
The support structure acts as an intermediary component that bridges the laser diode and the standard PCB. This approach avoids the need for complex protruding portion structures in the PCB itself, as the support structure provides the necessary mechanical and electrical interface functions.
4Ease of operation
If the laser diode is mounted to the protruding portion of the multilayer PCB, then electrical connection is achieved, but the laser diode is recessed into the through-hole which requires sharp bends in the optical fiber cable
Solution Approach 1:
The support structure elevates the laser diode mounting position in the vertical dimension, positioning it above the PCB surface rather than recessing it into a through-hole. This dimensional change allows the optical fiber cable to connect directly to the elevated laser diode without requiring sharp bends, improving the cable path geometry.
Data Source
AI summary
An adapter for electrically connecting a laser diode to a circuit board is disclosed. An example laser diode may form part of an optical communications system in which the laser diode emits optical signals into an optical fiber cable based on electrical signals received from one or more source circuits. The laser diode is electrically connected to the source circuit(s) through a circuit board. A laser diode adapter is provided to facilitate electrically connecting, as well as mechanically coupling, the laser diode to the circuit board. In this regard, the laser diode adapter includes conductive pads for coupling to conductive legs of the laser diode. The laser diode adapter also includes a set of conductive signal pads for coupling to conductive receiving pads which are electrically connected to the conductive pads, thereby electrically connecting the conductive legs of the laser diode to the circuit board.