Optical Block Passive Alignment for Optical Modules
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Solution Overview
Problem
Existing optical modules face challenges with optical alignment errors, high costs, and complex manufacturing processes due to the need for active alignment and miniaturization issues in high-speed data transmission, particularly in devices like optical connectors and modules.
Innovation Solution
An optical module design featuring a modularized structure with a passive optical alignment method, where the optical transmission member mounting portion is formed at an optimal position on an optical block, allowing for efficient optical alignment without active alignment processes, and using a minimal number of components to ensure reliable mounting and reduced manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If active optical alignment is used to correct mounting position errors, then optical transmission efficiency is improved, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent performs preliminary action by pre-calculating the optimal mounting position of the optical transmission member based on the actual mounting position of the optical element. This allows the mounting portion to be formed at the correct position before the optical element is mounted, eliminating the need for time-consuming active alignment processes during mass production while maintaining high optical transmission efficiency
Solution Approach 2:
The patent uses copying by measuring the actual mounting position of the optical element and using this information to determine the corresponding optimal position for the optical transmission member. This copying approach transfers the positional information from the optical element to the mounting portion design, enabling passive alignment that works with manufacturing variations without requiring active alignment processes
2Volume of moving object
If the number of components is reduced for miniaturization, then device size is reduced, but manufacturing precision and assembly ease deteriorate
Solution Approach 1:
The patent merges the optical element mounting position information with the optical transmission member mounting portion design. By integrating the position measurement and calculation functions into the mounting portion formation process, the system achieves miniaturization without sacrificing alignment precision, as the mounting portion is designed to compensate for manufacturing variations rather than requiring additional alignment components
Solution Approach 2:
The patent applies parameter changes by using the measured actual mounting position parameters of the optical element to determine the optimal mounting position parameters for the optical transmission member. This dynamic parameter adjustment allows the system to maintain high alignment precision in miniaturized designs by adapting to actual manufacturing variations rather than relying on fixed tolerance specifications
3Ease of manufacture
If passive optical alignment is used to simplify manufacturing, then manufacturing cost and time are reduced, but optical transmission efficiency may deteriorate due to mounting errors
Solution Approach 1:
The patent performs preliminary action by pre-calculating and forming the mounting portion at the optimal position based on the actual optical element mounting position before final assembly. This preliminary positioning ensures that even with manufacturing errors, the optical transmission member will be correctly aligned with the optical element, maintaining high transmission efficiency while using simple passive alignment processes
Solution Approach 2:
The patent implements feedback by measuring the actual mounting position of the optical element and using this information to determine the optimal position for the optical transmission member mounting portion. This feedback mechanism allows the passive alignment design to compensate for manufacturing variations, ensuring reliable optical transmission efficiency without requiring complex active alignment processes
Data Source
AI summary
An optical module includes optical transmission member, optical element, substrate, electrode pad between the optical element and external circuit, and optical block including optical transmission member mounting portion. The optical transmission member mounting portion is formed on the optical block in optical axis direction such that optical transmission efficiency is the maximum. A manufacturing method of the optical module includes mounting and electrically connecting the optical element on one face of the substrate, calculating a position on a 2-dimensional plane of optical input/output point of the optical element, forming base material of the optical block to impregnate the optical element onto the substrate, forming the optical transmission member mounting portion at the position on the 3-dimensional plane of the optical input/output point calculated in the former step on the base material, and mounting the optical transmission member on the optical transmission member mounting portion.