Optical Interconnection Module Alignment via Integrated Coupling Element
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Solution Overview
Problem
Current optical interconnection modules face challenges in accurately aligning optoelectronic elements with substrates, requiring additional processes and increasing costs due to complex fabrication and alignment inaccuracies.
Innovation Solution
An optical interconnection module design that incorporates optical coupling elements with matching and alignment elements, allowing direct alignment and assembly without additional processes, enhancing optical coupling efficiency by forming these elements during the final surface process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additional alignment processes and elements (such as index matching layers, alignment balls, V-grooves) are added to improve alignment accuracy, then manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the alignment function and optical coupling function into a single integrated optical coupling element. This element includes both the optical coupling structure and alignment structures (such as positioning protrusions and positioning grooves) that work together to achieve accurate alignment between the optoelectronic element and substrate while reducing the need for separate alignment components and processes
Solution Approach 2:
The alignment structures are pre-formed on the optical coupling element during its fabrication process. The positioning protrusions and grooves are created in advance to guide and constrain the relative positions of the optoelectronic element and substrate, enabling automatic alignment during assembly without requiring additional alignment steps
2Reliability
If multiple separate components (optical receiver, optical transmitter, transparent polymer, microlens arrays) are used to achieve optical coupling, then optical coupling efficiency improves, but the number of additional processes increases
Solution Approach 1:
The patent integrates multiple functions (optical coupling, alignment, and sealing) into a single optical coupling element. This eliminates the need for separate transparent polymer layers and microlens arrays, reducing the number of assembly steps while maintaining optical coupling efficiency through the integrated design
Solution Approach 2:
The optical coupling element serves multiple functions simultaneously: it provides optical coupling between the optoelectronic element and substrate, incorporates alignment structures for position registration, and acts as a protective and sealing component. This multi-functionality reduces the total component count and simplifies the packaging process
3Manufacturing precision
If alignment is achieved through separate alignment mechanisms (alignment balls, V-grooves, solder balls) followed by welding processes, then alignment can be accomplished, but processing time and complexity increase
Solution Approach 1:
The alignment structures are pre-formed on the optical coupling element during its fabrication process. The positioning protrusions and grooves are created in advance to guide and constrain the relative positions of the optoelectronic element and substrate, enabling automatic alignment during assembly without requiring additional alignment steps
Solution Approach 2:
The optical coupling element's integrated alignment structures enable the assembly to self-align during the bonding process. The positioning protrusions fit into the positioning grooves automatically, allowing the system to achieve accurate alignment through its own geometric constraints rather than requiring external alignment tools or multiple adjustment steps
Data Source
AI summary
An optical interconnection module includes at least one optoelectronic element, at least one substrate, and at least one optical coupling element. A plurality of matching elements is formed on one side of the optical coupling element opposite to the optoelectronic element and the substrate. A plurality of alignment elements is formed in the optoelectronic element and the substrate at positions corresponding to the matching elements. The matching elements and alignment elements are engaged with each other for alignment, such that the optoelectronic element, the substrate and the optical coupling element are directly aligned during assembly. Moreover, the optical coupling element is used to increase the optical coupling efficiency of the optoelectronic element and an optical waveguide formed on the substrate.