Lens Standoff Frame for Optical Communication Alignment
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Solution Overview
Problem
In optical communication systems, mechanical tolerances and forces can adversely affect the alignment and integrity of optical signals due to the critical spacing between laser chips and lens elements, leading to improper collimation and potential damage to fragile lens components.
Innovation Solution
An opto-electronic system with a frame that accurately controls the distance between the laser chip and the lens device, using a frame mounting portion and a lens mounting portion to maintain precise alignment, and a gap between the lens device and the housing to absorb forces, thereby minimizing the impact of mechanical tolerances and protecting the lens from damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the distance between laser chip and lens element is increased to accommodate mechanical tolerances, then manufacturing ease is improved, but optical alignment precision deteriorates
Solution Approach 1:
A lens block is introduced as an intermediary component between the laser chip and the lens element. The lens block serves as a mechanical mediator that defines a precise reference surface for lens mounting, isolating the optical path from mechanical tolerances in the laser chip positioning. This allows the laser chip to be mounted with standard tolerances while maintaining precise optical alignment through the lens block's reference surfaces.
Solution Approach 2:
The lens block is pre-mounted on the substrate with precision reference surfaces established before the laser chip is mounted. This preliminary action creates a stable optical reference framework that compensates for subsequent mechanical tolerances in laser chip positioning, ensuring consistent optical alignment without requiring ultra-precise laser chip mounting.
2Reliability
If optical connector applies force to lens block to ensure connection, then connection reliability is improved, but lens element displacement increases
Solution Approach 1:
The optical connection interface is segmented into separate functional zones: a connection interface that accepts optical connector force, and an optical path zone with the lens element. The lens block's reference surface is positioned to isolate the lens element from connection forces, allowing the connection interface to bear mechanical loads without transmitting them to the lens element, thus maintaining both connection reliability and lens alignment.
Solution Approach 2:
The lens block acts as a mechanical intermediary that absorbs and distributes connection forces from the optical connector. Its reference surface provides a stable mounting platform for the lens element that is mechanically isolated from the forces applied during connection, preventing lens element displacement while ensuring reliable optical connection.
3Stability of the object's composition
If optical connector contacts lens block directly, then connection stability is improved, but lens block damage risk increases
Solution Approach 1:
The lens block is designed with a reinforced structure and precise reference surfaces that provide inherent mechanical cushioning and protection. The reference surface is positioned and dimensioned to distribute connection forces away from the lens element, and the lens block's physical structure includes features that cushion against excessive forces, preventing damage before it occurs while maintaining stable optical connection.
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 ensures proper collimation of optical signals by maintaining accurate alignment and protecting the lens from displacement and damage, enhancing signal integrity and the reliability of the optical communication module.
Implementation Method 1
Lens element 24 collimates the beam or optical signals 20 emitted by laser chip 14
Data Source
AI summary
An opto-electronic system includes a substrate, an opto-electronic chip mounted on the substrate, a frame, and a lens device retained in the frame. A frame mounting portion of the frame is in contact with an upper surface of the opto-electronic chip. A lens mounting portion of the frame is spaced above the frame mounting portion. A lower surface of the lens device is in contact with the lens mounting portion. The spacing of the lens mounting portion and frame mounting portion determines the spacing between the upper surface of the opto-electronic chip and the lower surface of the lens device.