Optical Ferrule Assembly for Parallel Fiber Alignment
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Solution Overview
Problem
The alignment of multiple lasers or photodetectors with optical fibers in parallel optical modules is time-consuming, requires additional components, and precision pick-and-place techniques, especially when including both out-going and in-coming optical signals within a small form-factor module, which complicates the alignment process and increases the need for accurate equipment.
Innovation Solution
A method and apparatus for aligning optoelectronic devices with a single structure containing multiple optical waveguides, where each optoelectronic chip is independently aligned to the optical guiding structure, allowing for a low-profile, robust sub-component with reduced manufacturing costs and eliminating the need for precision pick-and-place equipment by tolerating variations in positional and rotational alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple lasers and photodetectors are aligned with optical fibers using traditional precision pick-and-place techniques, then alignment precision is improved, but assembly time and manufacturing cost increase significantly
Solution Approach 1:
The patent divides the alignment process into two independent stages: first aligning the VCSEL array to the optical ferrule, then aligning the photodetector array to the optical ferrule. This segmentation eliminates the need for complex multi-component simultaneous alignment, reducing assembly time while maintaining precision through independent optimization of each alignment stage.
Solution Approach 2:
The optical ferrule serves as an intermediary component that mediates the alignment between the VCSEL array and photodetector array. By providing a stable reference framework with precisely positioned optical fibers, the ferrule enables both arrays to be aligned independently to it, simplifying the overall alignment process and reducing manufacturing complexity.
2Manufacturing precision
If additional alignment components like relay microlenses and dowel pin alignment posts are added, then alignment accuracy is improved, but device complexity increases
Solution Approach 1:
The patent extracts and eliminates unnecessary intermediate alignment components from the traditional design. By using the optical ferrule as the primary alignment reference and directly mounting the VCSEL and photodetector arrays to it, the design removes relay microlenses and dowel pin alignment posts, simplifying the structure while maintaining alignment accuracy through precise ferrule fabrication and direct coupling.
3Productivity
If VCSEL arrays and photodetector arrays are aligned together on 250-micron pitch, then bandwidth-density is improved, but alignment difficulty and equipment requirements increase
Solution Approach 1:
The patent segments the high-density alignment task into two separate, lower-complexity alignment operations. Each array (VCSEL and photodetector) is aligned independently to the optical ferrule rather than to each other, reducing the complexity from simultaneous multi-component alignment to two simpler independent alignment stages while maintaining the 250-micron pitch bandwidth-density advantage.
Data Source
AI summary
There is provided an optical assembly and a method for assembling components of the optical assembly, the method comprising: providing a structure for guiding light; providing a plurality of optical fibers embedded in a fixed arrangement in the structure, the optical fibers for coupling the light from a coupling surface the structure; abutting a first package against the coupling surface, such that each one of multiple elements comprised in the first package is substantially aligned with each one of a first group of optical fibers in the plurality of optical fibers; and abutting a second package against the coupling surface, adjacent to the first package, and such that: the first and the second package are spaced apart by a gap; and each one of multiple elements comprised in the second package is substantially aligned with each one of a second group of optical fibers in the plurality of optical fibers, the gap providing a tolerance in a position of any one of: each one of the elements in the packages; the packages with respect to each other; and each one of the packages with respect to the structure.