Optical Sub-Assembly Housing for Transceiver Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current main housings for optical sub-assemblies in transceivers face challenges in stabilizing the optical filter's angular position, leading to performance losses due to machining limitations, which affect optical coupling and alignment.
Innovation Solution
A T-shaped main housing structure comprising a metal cylindrical member and a plastic bypass member, where the bypass member is injection-molded to connect with the cylindrical member, forming a precise 45-degree filter holder position using a connection tube and sleeve, ensuring stable optical filter alignment and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the optical filter is affixed to a frame of a filter holder and a locating pin is used to lock the filter holder in a fixed position, then the optical filter can be positioned in the main housing, but the optical filter cannot be stably located in the true angular position due to machining limitations
Solution Approach 1:
The patent merges the filter holder and the main housing into a single integrated structure. The filter holder is formed as an integral part of the main housing body, eliminating the need for separate locating pins and frames. This integration ensures that the optical filter is automatically positioned at the precise 45-degree angle through the inherent geometric design of the integrated structure, achieving true angular positioning without the complexity of separate positioning components.
Solution Approach 2:
The patent introduces a precision-machined reference surface or datum feature within the integrated housing structure that serves as an intermediary reference for positioning the optical filter. This reference feature ensures that the filter is automatically aligned at the correct 45-degree angle during assembly, eliminating the need for separate locating pins while maintaining high angular precision.
2Manufacturing precision
If multiple separate components (main housing, filter holder, locating pin) are used to position the optical filter, then the assembly process becomes complex and costly, but the optical filter alignment precision is compromised
Solution Approach 1:
The patent combines the main housing and filter holder into a single integrated component manufactured as one piece. This eliminates the need for separate locating pins and multiple assembly steps, significantly reducing manufacturing complexity and cost. The integrated structure inherently provides precise 45-degree positioning of the optical filter through its geometric design, achieving both high alignment precision and ease of manufacture.
Solution Approach 2:
The patent incorporates the positioning geometry for the optical filter directly into the tooling and molding process during manufacturing of the integrated housing. The precise 45-degree angle is built-in during the initial manufacturing stage rather than requiring subsequent assembly operations, thereby simplifying the overall manufacturing process and reducing costs while maintaining high precision.
3Manufacturing precision
If mechanical processing is used to form the main housing, then the housing can be manufactured, but a 45-degree holder cannot be directly formed inside the main housing
Solution Approach 1:
The patent changes the manufacturing method from traditional mechanical machining to injection molding or precision casting. These processes can directly form complex three-dimensional geometries including precise 45-degree angles and curved surfaces within the main housing body in a single operation, eliminating the need for multiple sequential machining operations and tool changes.
Solution Approach 2:
The patent incorporates the 45-degree holder geometry directly into the mold or casting pattern during the initial manufacturing process. This allows the complex angular features to be formed in one step during the primary manufacturing operation, rather than requiring subsequent secondary machining operations to create the precise angular positioning features.
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
Enhances optical coupling and alignment, reduces manufacturing costs by simplifying the assembly process, and maintains the filter's focal position stability, thereby improving transmission performance.
Implementation Method 1
The light emitted from the laser diode element 1a is refracted and coupled to an optical fiber 9a via the optic filter 6
Implementation Method 2
The received light is totally reflected to the light detection element 2a through the optical filter 6
Implementation Method 3
The sleeve 11 is affixed to the main housing 4 by laser welding
Data Source
AI summary
A main housing for optical sub-assembly for transceivers includes a cylindrical member and a bypass member. The cylindrical member has a first end for accommodating an optical transmission unit and a second end for accommodating an optical fiber connector. A tubular member forming groove is formed on an outer circumference of the cylindrical member. A sleeve forming reference hole is formed on a tubular wall of the cylindrical member in communication with the tubular member forming groove. The bypass member has a connection tube positioned in the tubular member forming groove, a filter holder positioned in the cylindrical member and connected with the connection tube for connecting a filter on the filter holder, and a sleeve for accommodating an optical receiving unit. The sleeve outward extends along the sleeve forming reference hole and is connected with the filter holder.