Optical Interposer Assembly for Passive Fiber Alignment
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Solution Overview
Problem
Existing optical subassemblies (OSAs) face challenges in providing simplified platforms for passive alignment and direct optical coupling, which complicates manufacturing and reduces optical performance.
Innovation Solution
An interposer with alignment apertures and direct optical coupling features, allowing for precise passive alignment and integration of optical and electronic components on a single substrate, eliminating the need for light bending and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional optical subassemblies are used without an interposer, then manufacturing processes become complex and alignment precision deteriorates, but the device structure remains simpler
Solution Approach 1:
An interposer substrate is introduced as an intermediary component between the circuit board and optical components. The interposer provides alignment apertures that precisely position optical components and fibers, while also containing electrical traces for signal routing. This mediator resolves the contradiction by enabling high alignment precision through its aperture structures without requiring direct complex assembly between the circuit board and optical components.
Solution Approach 2:
The optical subassembly is segmented into distinct functional layers: the circuit board layer, the interposer layer with alignment apertures and electrical traces, and the optical component layer. This segmentation allows each layer to be optimized independently - the interposer handles alignment and electrical connections, while the optical components focus on optical functionality, thereby improving alignment precision without overwhelming device complexity.
2Reliability
If direct optical coupling is implemented, then optical performance improves and signal loss reduces, but manufacturing complexity increases
Solution Approach 1:
The interposer is prepared in advance with precisely positioned alignment apertures and electrical traces before optical components are mounted. This preliminary action establishes the alignment framework beforehand, allowing optical components to be directly coupled with pre-positioned fibers or lenses, thereby achieving high optical performance while simplifying the actual assembly process through pre-established alignment features.
Solution Approach 2:
The interposer serves as a mediator that facilitates direct optical coupling between optical components and fibers. By providing alignment apertures and holding structures, the interposer enables precise direct coupling without requiring complex external alignment mechanisms, thus improving optical performance while maintaining ease of manufacture.
3Loss of time
If passive alignment is enabled through alignment apertures, then alignment time reduces and manufacturing simplifies, but the interposer structure becomes more complex
Solution Approach 1:
The alignment apertures in the interposer are designed to automatically guide and position optical components and fibers during assembly without requiring external alignment tools or procedures. The aperture geometry itself provides the alignment function, allowing components to self-align as they are placed into the apertures, thereby reducing alignment time while the interposer structure assumes the complexity of providing these precise aperture features.
Data Source
AI summary
An optical subassembly comprising: (a) an interposer having first and second opposing sides and defining an alignment aperture extending from said first opposing side to said second opposing side, said interposer defining traces having contacts; (b) a fiber having a first optical axis, said fiber being held such that first optical axis is positioned essentially orthogonal to said first and second opposing sides; (c) at least one optical component mounted to said second opposing side and being electrically connected to at least a portion of said contacts, said at least one optical component having a second optical axis coincident with said first optical axis; and (d) a circuit board configured to receive said interposer such that said interposer is essentially orthogonal to said circuit board and said first optical axis is essentially parallel to said circuit board, said circuit board being electrically connected to at least a portion of said contacts.