Optical Block Passive Alignment for Multi-Lane Module Assembly
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Solution Overview
Problem
The complex assembly process and long cycle time in manufacturing optical transmission modules with multiple lanes, due to the need to adjust various optical components for maximum coupling efficiency, and the high cost of methods requiring external operation signals and special elements.
Innovation Solution
A method involving a spatial optical system with collimating lenses, an optical multi-demultiplexer, a coupling lens, and a transparent optical block, where the positions and angles of the collimating lenses and SMF are adjusted to maximize coupling efficiency without active alignment of the optical multi-demultiplexer and coupling lens, using a simplified assembly process and passive alignment techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If active alignment is performed to maximize coupling efficiency for all lanes, then coupling efficiency is improved, but assembly process complexity and cycle time increase
Solution Approach 1:
The optical block is positioned and angled during the passive alignment process before final assembly, preliminarily establishing the optical path geometry. This preliminary positioning allows subsequent components to be aligned relative to this fixed reference, eliminating the need for complex active adjustment during final assembly while maintaining high coupling efficiency across all lanes.
Solution Approach 2:
The optical block serves as an intermediary element that mediates between the collimating lenses and the optical multi-demultiplexer. By providing a fixed reference surface and controlled optical path, it enables passive alignment of other components without requiring complex active adjustment mechanisms, thus simplifying the assembly process while maintaining precision.
2Manufacturing precision
If active alignment is performed to maximize coupling efficiency for all lanes, then coupling efficiency is improved, but assembly cycle time increases
Solution Approach 1:
The passive alignment system enables components to self-align through mechanical fixtures and reference surfaces without requiring complex active adjustment mechanisms. The optical block's fixed position and angle provide a self-referencing framework that guides other components into proper alignment automatically, significantly reducing assembly cycle time while maintaining high coupling efficiency.
Solution Approach 2:
Critical alignment parameters are established in advance during fixture design and optical block positioning, rather than during final assembly. This preliminary establishment of geometric relationships allows rapid assembly without time-consuming active adjustments, thereby increasing productivity while preserving manufacturing precision.
3Manufacturing precision
If methods using liquid crystal elements or non-linear optical elements are used to change beam direction, then beam deflection control is improved, but cost increases due to external operation signals and special elements
Solution Approach 1:
The invention extracts and eliminates the need for expensive liquid crystal elements, non-linear optical elements, and external operation signal systems. Instead, beam direction control is achieved through the geometric configuration of simple optical components (collimating lenses, optical block, and multi-demultiplexer), removing costly elements while maintaining manufacturing precision.
Solution Approach 2:
The invention replaces expensive, complex optical elements (liquid crystal devices, non-linear optical elements) with simple, inexpensive passive optical components (lenses and mirrors). These simple components achieve the same beam direction control function at a fraction of the cost, making the system economically viable for mass production.
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 approach achieves high coupling efficiency for all lanes without adjusting the optical multi-demultiplexer and coupling lens positions, simplifies the assembly process, reduces cycle time, and eliminates the need for costly external operation signals and special elements, enhancing reliability and cost-effectiveness.
Implementation Method 1
an optical multi-demultiplexer using reflection of light caused by a spatial optical system
Implementation Method 2
a plurality of collimating lenses individually provided in the optical elements, each of the collimating lenses having a first end facing a main surface of one of the optical elements
Implementation Method 3
a coupling lens having a first end facing a second end of the optical multi-demultiplexer; a single mode optical fiber having one end facing a second end of the coupling lens
Data Source
AI summary
There are provided: a plurality of optical elements for handling light having different wavelengths; a plurality of collimating lenses individually provided in the optical elements, each of the collimating lenses having a first end facing a main surface of one of the optical elements; an optical multi-demultiplexer using reflection of light caused by a spatial optical system, the optical multi-demultiplexer having a first end facing a second end of each of the collimating lenses; a coupling lens having a first end facing a second end of the optical multi-demultiplexer; an SMF having one end facing a second end of the coupling lens; and an optical block, which is transparent, provided on an optical path between each of the collimating lenses and the optical multi-demultiplexer, the optical path having a small number of reflections in the optical multi-demultiplexer.