Optical Component Alignment with Three Translational Degrees
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Solution Overview
Problem
The increased complexity in aligning optical transceiver components due to their unified design on a single substrate has led to stringent alignment requirements, resulting in higher costs and inefficiencies in achieving sub-micron accuracy for fiber optic networks.
Innovation Solution
The alignment of optical components with three degrees of translational freedom is achieved by mechanically coupling a lens pin to a lens base and a molded package in multiple directions, optimizing signal strength through a method that includes initial alignment, coupling, and realignment to ensure precise positioning and secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If optical components are unified on a single substrate, then transceiver design is simplified, but alignment complexity and cost increase dramatically
Solution Approach 1:
The alignment process is segmented into three distinct stages: first aligning the lens pin in the Z-direction, then aligning the lens base in the X-direction, and finally aligning the molded package in the Y-direction. This segmentation allows each alignment operation to focus on a single degree of freedom, dramatically simplifying the overall manufacturing process while maintaining sub-micron accuracy requirements.
2Manufacturing precision
If manual alignment methods are used, then sub-micron accuracy can be achieved, but alignment time and productivity are significantly reduced
Solution Approach 1:
The lens pin is pre-aligned in the Z-direction (optical axis) before final assembly, establishing a preliminary alignment that maintains optical precision. This preliminary positioning allows subsequent X and Y alignment operations to focus only on lateral positioning, achieving sub-micron accuracy more efficiently than complete manual realignment would require.
Solution Approach 2:
The alignment system incorporates dynamic adjustment capabilities where components can be repositioned along specific axes independently. The lens pin, lens base, and molded package each have controlled freedom to move in their respective alignment directions, enabling automated systems to rapidly achieve precise alignment without the time-consuming manual manipulation traditionally required.
3Manufacturing precision
If multiple alignment operations are performed sequentially, then positioning accuracy is maintained, but total alignment time increases
Solution Approach 1:
The alignment process is divided into three independent sequential operations, each addressing a single degree of freedom. This segmentation allows for optimized execution where each alignment step can be performed by specialized automated equipment rather than general-purpose manual tools, reducing the time penalty associated with multiple alignment operations while maintaining cumulative positioning accuracy.
Data Source
AI summary
The principles of the present invention relate to aligning optical components with three degrees of translational freedom. A lens pin, a lens base, and a molded package are aligned in a first direction, a second direction, and a third direction such that the signal strength of optical signals transferred between a lens included in the lens pin and the molded package is optimized. The lens pin is mechanically coupled to the lens base to fix the position of the lens relative to the molded package in the first direction. Subsequently, the lens base and the molded package are realigned in the second and third directions such that the signal strength is again optimized. The lens base is mechanically coupled to the molded package to fix the position of the lens base relative to the molded package in the second and third directions.