Lens Mounting Structure for Optical Modules Using UV Parallel Light
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Solution Overview
Problem
In the manufacturing of optical transceiver modules, the precision of optical alignment and the bonding process is challenging due to non-uniform epoxy curing characteristics, leading to optical alignment errors caused by contraction forces during the curing of epoxy adhesive, especially in narrow spaces with limited light irradiation and interference from structural components.
Innovation Solution
A highly integrated multi-channel optical module with a lens mounting structure that uses UV parallel light and reflectors on the lens mount unit to uniformly cure the epoxy adhesive, minimizing optical alignment errors by ensuring symmetrical curing and reducing contraction force non-uniformity, where the UV light path is formed using inclined reflectors on the side surfaces of the lens mount unit to accurately irradiate the adhesive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If UV light is irradiated from the outside to cure epoxy adhesive, then the bonding process can be completed, but non-uniform curing characteristics occur due to limited light irradiation in narrow spaces, causing optical alignment errors
Solution Approach 1:
A transparent window is introduced as an intermediary component between the UV light source and the epoxy adhesive. This window allows UV light to pass through uniformly to cure the epoxy from below, while also serving as part of the lens mounting structure. The window mediates the light transmission problem by providing a dedicated optical path that is not blocked by the narrow space constraints or structural components above the adhesive.
Solution Approach 2:
The curing approach is changed from vertical irradiation (from above through narrow spaces) to horizontal irradiation (from below through the window). By changing the dimension of light entry, the patent bypasses the obstruction problem caused by structural components in the vertical path and achieves uniform light distribution across the epoxy adhesive area.
2Strength
If epoxy adhesive is used to fix the lens, then bonding can be achieved, but contraction forces during curing cause optical alignment errors
Solution Approach 1:
Optical alignment is performed and fixed in the preliminary stage before epoxy curing begins. The lens and optical components are positioned and aligned with high precision, then the epoxy is applied and cured without further adjustment. This preliminary action ensures that the alignment state is captured before the contraction forces during curing can cause displacement.
Solution Approach 2:
The patent compensates for the expected contraction forces by using a large-area window that distributes the UV light uniformly, ensuring even curing throughout the epoxy volume. This uniform curing minimizes differential contraction forces that would otherwise cause distortion. The preliminary design of the window structure anticipates and counteracts the harmful contraction effects.
3Productivity
If multi-channel optical devices are integrated in narrow spaces, then high integration is achieved, but light irradiation is limited causing non-uniform epoxy curing
Solution Approach 1:
The patent changes the light irradiation dimension from vertical (through narrow spaces between channels) to horizontal (through the window from below). This dimensional change allows UV light to access and uniformly cure epoxy in all channels simultaneously without being blocked by the narrow vertical spaces or adjacent optical components.
Solution Approach 2:
The window serves multiple functions: it acts as part of the lens mounting structure, provides a transparent path for UV light transmission, and distributes light uniformly across all channels. This multi-functionality allows the same component to support both the mechanical mounting and the optical curing process, achieving high integration without compromising curing uniformity.
4Adaptability or versatility
If structural components are present in narrow spaces, then device functionality is maintained, but they interfere with light irradiation to epoxy adhesive
Solution Approach 1:
The transparent window acts as an intermediary optical path that bypasses the structural components. Instead of trying to irradiate light through or around the obstructing components, the window provides a dedicated light path from below that is not blocked by the structural elements above the epoxy adhesive.
Solution Approach 2:
Instead of irradiating light from above (through the structural components), the patent inverts the approach and irradiates from below through the window. This reversal of the light direction avoids the interference from structural components entirely, as the irradiation path is established from the opposite side where obstructions are minimized.
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 minimizes optical alignment errors and shortens the epoxy curing time, enhancing productivity by ensuring uniform epoxy curing and reducing the risk of defects like air bubbles or cracks, thus improving the efficiency of the lens assembly process.
Implementation Method 1
epoxy is changed from an initial liquid state to a gel state which is a semisolid state, on the basis of light of an ultraviolet (UV) band and is cured in a solid state
Implementation Method 2
a light path of the UV parallel light is formed in the lens mount unit by a reflector attached on a side surface of the lens mount unit, and the UV parallel light moves along the light path
Data Source
AI summary
A highly integrated multi-channel optical module is provided. The optical module includes an optical source device mounted on a substrate by an optical source mount unit, a waveguide mounted on the substrate by a waveguide mount unit, a lens mount unit disposed between the optical source device and the waveguide and mounted on the substrate, and a lens unit fixed to the lens mount unit by an adhesive cured by ultraviolet (UV) parallel light, wherein a light path of the UV parallel light is formed in the lens mount unit by a reflector attached on a side surface of the lens mount unit, and the UV parallel light moves along the light path and cures the adhesive coated on an upper portion of the lens mount unit facing a lower end portion of the lens unit.