Optical Element Alignment via Reference Holes and Loose Post Fit
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Solution Overview
Problem
Conventional optical transceivers are costly, bulky, and prone to alignment errors due to complex structures and tolerance issues in hole and post coupling, making them unsuitable for mobile applications and requiring improved manufacturing efficiency and precision.
Innovation Solution
An optical element alignment method using a baseplate with a first reference hole and a second reference hole, spaced by a specific distance, along with an optical-fiber-fixing block featuring a first post and a second post, where the second post is inserted into the second reference hole in a looser manner than the first post into the first hole, to achieve precise optical alignment with reduced assembly complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional hole and post coupling structure is used for optical alignment, then assembly is simplified, but alignment precision deteriorates due to tolerance gaps
Solution Approach 1:
The patent applies preliminary action by pre-forming precise reference holes directly on the substrate before mounting the optical element. These reference holes serve as predetermined alignment markers that guide the positioning of the optical element and subsequent components, eliminating the need for complex post-assembly alignment adjustments while ensuring high precision.
Solution Approach 2:
The patent introduces reference holes as intermediary elements that mediate between the substrate and the optical element. These reference holes act as a reference framework that enables precise alignment without requiring tight tolerances in the hole-post coupling itself, thus resolving the contradiction between assembly simplicity and alignment precision.
2Manufacturing precision
If additional injection molded structures are added for precise alignment, then alignment precision improves, but device complexity and cost increase
Solution Approach 1:
The patent merges the alignment reference function directly into the substrate by forming reference holes on the substrate itself, rather than adding separate alignment structures. This integration eliminates the need for additional injection molded alignment components, reducing device complexity and cost while maintaining high alignment precision.
Solution Approach 2:
The substrate is given multiple functions: it serves both as the mounting platform for the optical element and as the source of alignment references through the reference holes. This multi-functionality eliminates the need for separate alignment structures, reducing overall device complexity while ensuring precise alignment.
3Manufacturing precision
If tight coupling between hole and post is used, then alignment precision improves, but manufacturing tolerance becomes harder to achieve
Solution Approach 1:
The patent uses preliminary action by pre-forming reference holes with precise dimensions and positions on the substrate before assembly. These reference holes establish a fixed reference framework that defines the alignment requirements, allowing subsequent components to be manufactured with relaxed tolerances while still achieving high overall alignment precision.
Data Source
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AI summary
An optical element alignment method is disclosed. In technical fields that require a high level of precision, at least one embodiment of the present disclosure provides a method for aligning an optical element, which minimizes optical alignment deviations to overcome the difficulty of a conventional optical element alignment method to meet the required optical alignment tolerance.