Optical Communication Module Passive Alignment Ferrule

Solution Overview

Problem

Conventional optical communication modules face misalignment issues during assembly, leading to erroneous signal transmission and conversion, which impairs product yield and quality due to mechanical alignment processes being prone to external forces and lack of precise optical alignment.

Innovation Solution

An optical communication module with a lens carrier and substrate using passive alignment marks and glue-guiding grooves for precise alignment and secure fixation, combined with a ferrule and clipping element for enhanced stability and coupling performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If mechanical alignment is used during assembly, then the components can be connected, but misalignment occurs due to external forces and lack of precision

Engineering Contradiction:

Improvealignment precisionVSAvoidassembly stability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent applies preliminary action by pre-defining alignment marks on both the lens carrier and substrate before assembly. These alignment marks are precisely positioned during manufacturing, enabling the lens carrier to be accurately aligned with the substrate through passive alignment during assembly, thereby preventing misalignment caused by external forces and ensuring high manufacturing precision and assembly stability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the conventional active mechanical alignment system with a passive alignment system. Instead of using complex mechanical adjustment mechanisms during assembly, the invention uses pre-defined alignment marks and corresponding alignment structures that automatically guide the lens carrier to its precise position on the substrate, eliminating the need for manual mechanical adjustment and reducing sensitivity to external forces

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If conventional mechanical alignment is used, then assembly can proceed, but product yield and quality are impaired due to misalignment

Engineering Contradiction:

Improveproduct yieldVSAvoidoptical alignment precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-defining alignment marks on both the lens carrier and substrate before assembly. These alignment marks are precisely positioned during manufacturing, enabling the lens carrier to be accurately aligned with the substrate through passive alignment during assembly, thereby preventing misalignment caused by external forces and ensuring high manufacturing precision and assembly stability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the conventional active mechanical alignment system with a passive alignment system. Instead of using complex mechanical adjustment mechanisms during assembly, the invention uses pre-defined alignment marks and corresponding alignment structures that automatically guide the lens carrier to its precise position on the substrate, eliminating the need for manual mechanical adjustment and reducing sensitivity to external forces

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If alignment marks are used for passive alignment, then precise optical alignment is achieved, but additional structural elements are required

Engineering Contradiction:

Improveoptical alignment precisionVSAvoidstructure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges the alignment mark structures with the functional components of the lens carrier and substrate. The alignment marks are integrated into the existing structural elements rather than being separate added components, thereby achieving precise optical alignment while minimizing additional structural complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The alignment structures serve multiple functions: they provide precise alignment guidance during assembly and also serve as part of the mechanical connection structure between the lens carrier and substrate. This multi-functionality reduces the need for separate alignment and connection components, thereby reducing overall structural complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS9011024B2Optical communication module and assembling method thereof

Publication Date: 2015.04.21 DELTA ELECTRONICS INC(CN)

AI summary

An optical communication module includes a substrate, a lens carrier, and a ferrule. The substrate includes at least two transmitter/receiver chips. The transmitter/receiver chips include plural optoelectronic units with respective alignment marks. The lens carrier includes a frame and a lens array. The lens array includes plural lens units corresponding to respective optoelectronic units of the transmitter/receiver chips of the substrate. The ferrule is coupled with the lens carrier. The alignment marks of the plural optoelectronic units are passively aligned with corresponding lens units, so that the lens carrier and the substrate are precisely aligned with each other and combined together. After the lens carrier and the substrate are combined together, the ferrule and the lens carrier are combined together, so that a precise optical communication path is constructed.