Multi-Channel Parallel Optical System Passive Alignment
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Solution Overview
Problem
Traditional passive alignment technologies for optoelectronic modules are limited in accommodating multiple-channel transmitters and receivers within a single small package, as they can only contain a single photodetector or laser and monitor photodetector, which is insufficient for increasing bandwidth demands in data transmission.
Innovation Solution
A multi-channel parallel optical system is developed using substrates with optical components and fiber placement grooves, where optical fibers are aligned and coupled with optical components through V-grooves and alignment pins, allowing for passive alignment and efficient optical coupling with high accuracy, enabling the integration of multiple lasers, photodetectors, and monitor photodetectors within a compact transceiver package.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional TO packaging method is used, then single photodetector or laser can be contained, but the package cannot accommodate multiple-channel transmitters and receivers for high bandwidth demands
Solution Approach 1:
The patent combines multiple optical components (lasers, photodetectors, monitor photodetectors) and electronic components into a single integrated optoelectronic module package, replacing multiple separate TO packages. This merging allows multiple-channel transmitters and receivers to coexist in one compact package, increasing bandwidth capacity without proportionally increasing volume.
Solution Approach 2:
The patent employs a nested structure where optical components are mounted on substrates that are integrated within the package, and electronic components are mounted on the same or adjacent substrates. This nesting approach maximizes space utilization, allowing multiple components to be arranged in three-dimensional space efficiently within the compact package volume.
2Productivity
If passive alignment process is used, then throughput and cost are improved, but alignment accuracy between fibers and optical components is difficult to achieve
Solution Approach 1:
The patent incorporates preliminary alignment features directly into the substrate design, including precision-machined mounting surfaces, alignment holes, and mechanical stops. These features are prepared in advance during substrate fabrication, enabling passive alignment during assembly without requiring complex active adjustment mechanisms. This preliminary preparation ensures high alignment accuracy while maintaining the simplicity and speed of passive alignment processes.
Solution Approach 2:
The patent uses alignment pins and mechanical fixtures as intermediaries to transfer and maintain precise positional relationships between optical components and fibers during assembly. These intermediary elements bridge the gap between components, ensuring accurate alignment through mechanical constraints rather than relying solely on component tolerances, thereby achieving high precision in passive alignment.
3Quantity of substance
If multiple optical components are integrated in compact package, then bandwidth density is improved, but device complexity increases
Solution Approach 1:
The patent segments the optoelectronic module into distinct functional sections on separate substrates: optical component mounting areas, electronic component mounting areas, and fiber coupling sections. Each substrate is designed with specific functions, allowing complex multi-channel functionality to be organized into manageable modular segments. This segmentation reduces overall package complexity by dividing the system into independent functional blocks that can be assembled systematically.
Solution Approach 2:
The patent designs multi-functional substrates that serve multiple purposes: providing mechanical support, electrical connections, thermal management, and optical alignment references. The substrates act as universal platforms that integrate various functions into single components, reducing the total number of separate parts needed and simplifying the overall package structure despite accommodating multiple channels.
Data Source
AI summary
The invention provides an optical system, in particular, a multi-channel parallel optical transceiver system and methods of forming the same. The multi-channel parallel optical system includes a first substrate with at least one optical component mounted on its first side, a second substrate with optical fibers affixed in fiber fixing structures (grooves), the second substrate being mounted on the first side of the first substrate perpendicular to the first side of the first substrate so that the optical signal can be transmitted and received between the optical fibers and the mounted optical components with minimum loss. Passive alignment assembly is realized by using a series of alignment pins and holes and/or grooves pre-fabricated on the substrates. The optical systems may additionally include other structures to provide additional functionalities, in-line monitor photodetectors, and mechanical support or substrate elevation.