Optical Module Alignment via Path Changing Unit
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Solution Overview
Problem
High-speed optical communication systems face inefficiencies in aligning optical elements within optical modules, leading to significant time consumption during active alignment processes, especially in devices with multiple channels.
Innovation Solution
An optical module design featuring a case with an accommodation portion for multiple optical elements, where optical waveguide cores are formed at positions corresponding to the optical axis centers, and an optical path changing unit is integrated at a predetermined angle to facilitate accurate alignment and reduce misalignment issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If active alignment is performed for each channel in multi-channel optical modules, then alignment precision is improved, but manufacturing time is significantly increased
Solution Approach 1:
The patent segments the alignment process into two distinct stages: (1) preliminary positioning using mechanical stops and fixture structures to establish rough alignment for all channels simultaneously, and (2) selective fine-tuning only for channels requiring higher precision. This segmentation avoids performing time-consuming active alignment on every channel while maintaining necessary alignment precision for critical channels.
Solution Approach 2:
The patent implements preliminary positioning actions through mechanically stopped positions and pre-aligned fixture structures before the actual active alignment process. These preliminary structures pre-establish the geometric relationships between optical components, reducing the scope and time required for subsequent active alignment operations.
2Manufacturing precision
If multiple optical elements are aligned individually, then alignment accuracy is improved, but device complexity increases
Solution Approach 1:
The patent designs universal alignment fixtures and mechanical stop structures that serve multiple functions: they provide preliminary positioning for all optical channels, establish reference geometries, and guide the active alignment process. These multi-functional structures reduce the need for separate alignment mechanisms for each channel, thereby simplifying the overall alignment process while maintaining accuracy.
Solution Approach 2:
The patent creates equipotential alignment conditions by designing fixture structures that provide consistent geometric references and mechanical constraints across all optical channels. This ensures that all channels start from equivalent positioning conditions, simplifying the alignment process and reducing the complexity of managing different alignment requirements for each channel.
3Reliability
If precise alignment is achieved through active alignment, then optical coupling efficiency is improved, but manufacturing cost increases
Solution Approach 1:
The patent segments the alignment effort by applying comprehensive active alignment only to critical optical channels where coupling efficiency is most sensitive, while using simpler mechanical positioning for less critical channels. This selective approach maintains necessary optical coupling efficiency for key functions while reducing overall manufacturing costs by avoiding unnecessary alignment complexity on all channels.
Solution Approach 2:
The patent uses pre-manufactured mechanical stop structures and fixture-based preliminary positioning that are designed to achieve acceptable alignment accuracy without requiring time-consuming and expensive active alignment processes. These preliminary structures provide cost-effective positioning that reduces or eliminates the need for expensive active alignment equipment and operations.
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
This design enables efficient alignment of multiple optical elements, reducing optical coupling loss and simplifying the manufacturing process for high-channel-count optical modules by allowing a single alignment step to accurately position all elements, thus improving manufacturing yield and reducing costs.
Implementation Method 1
An optical path changing unit is formed at a position corresponding to the planar positions of the optical axis centers. The optical path changing unit faces the optical waveguide at a predetermined angle.
Data Source
AI summary
An optical module is provided with a case, which includes an accommodation portion, optical elements, optical waveguide cores, a clad layer, and an optical path changing unit. The optical elements are accommodated in and fixed to the accommodation portion. The optical elements have optical axis centers. The optical waveguide cores are respectively formed at positions corresponding to the planar positions of the optical axis centers. The clad layer surrounds the optical waveguide cores. The clad layer and the optical waveguide cores form an optical waveguide. The optical waveguide is stacked on a wiring substrate including a wiring pattern to which electrode terminals of the optical elements are connected, and the case is mounted on the wiring substrate. The optical path changing unit is formed at a position corresponding to the planar positions of the optical axis centers and faces the optical waveguide at a predetermined angle.