Lens Clip Aligning Optical Lens Array in Transceiver Assembly
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Solution Overview
Problem
The challenge in optical transceiver manufacturing lies in maintaining proper alignment and orientation of optical components, particularly due to post-annealing shift caused by UV-curing adhesives, which complicates the assembly process and reduces yield as channel density increases.
Innovation Solution
A lens clip with a mounting surface and optical lens slot that securely holds and aligns optical lenses relative to laser diodes and other components, allowing for group alignment and reducing the need for individual per-channel adjustments, while formed from transparent materials to minimize epoxy displacement and post-annealing shift.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If UV-curing optical adhesives are used to attach focusing lenses, then components can be securely attached to housing/substrate, but post-annealing shift occurs causing misalignment of components
Solution Approach 1:
A lens clip is introduced as an intermediary component between the focusing lens and the housing/substrate. The lens clip provides a mechanical alignment structure with alignment features that ensure precise positioning of the focusing lens relative to the laser diode and AWG, while the UV-curing adhesive is applied to attach the lens clip assembly to the substrate. This intermediary structure eliminates the direct attachment of adhesive to the lens, preventing post-annealing shift of the lens while still achieving secure attachment.
2Productivity
If multiple focus lenses are used in multi-channel optical subassemblies, then channel capacity increases, but alignment tolerance requirements become more stringent requiring multiple iterative adjustments
Solution Approach 1:
The optical subassembly is segmented into modular channel groups, where each channel or group of channels is independently aligned and tested before final assembly. The lens clip design allows for individual channel alignment without requiring iterative adjustment of all channels simultaneously. This segmentation approach enables parallel processing and reduces the complexity of multi-channel alignment.
Solution Approach 2:
Alignment features are pre-formed on the lens clip and substrate during manufacturing, establishing predetermined alignment references before the actual assembly process. The lens clip includes alignment protrusions that fit into corresponding alignment recesses on the substrate, and the focusing lens is pre-positioned on the lens clip with alignment features. This preliminary preparation of alignment structures eliminates the need for multiple iterative adjustments during final assembly.
3Reliability
If per-channel active alignment is performed for each laser and focus lens, then optimal optical coupling is achieved, but manufacturing complexity and time increase significantly
Solution Approach 1:
Multiple alignment functions are merged into the lens clip structure. The lens clip simultaneously provides mechanical support for the focusing lens, alignment references for both the lens and the laser diode, and mounting features for attachment to the substrate. This consolidation of alignment functions into a single component simplifies the manufacturing process while maintaining optimal optical coupling, eliminating the need for separate alignment procedures for each component.
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 solution simplifies manufacturing, reduces misalignment errors, and increases alignment tolerances, enabling the assembly of multi-channel TOSAs with higher channel counts without the need for iterative active alignment, thus improving the structural integrity and reliability of optical transceivers.
Implementation Method 1
UV-curing (UV-curing) optical adhesives
Data Source
AI summary
The present disclosure is generally directed to a lens clip that defines at least one mounting surface for coupling to and supporting an array of optical components, e.g., a laser diode and associated components, and an optical lens slot to receive and securely hold an array of optical lenses at a predetermined position relative to the optical components to ensure nominal optical coupling. The optical lens slot includes dimensions that permit insertion of each optical lens into the same and restrict travel along one or more axis. Accordingly, disposing an optical lens within the lens slot ensures correct alignment along at least two axis, e.g., Z and X, with the third axis (e.g., Y) extending parallel along the slot to permit lateral adjustment of each lens.