Optical Module Self-Alignment via Asymmetric Features
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Solution Overview
Problem
The alignment of optical components in optical communication systems is often inefficient, leading to suboptimal system performance and increased costs due to improper placement tolerance during assembly.
Innovation Solution
A self-alignment method for optoelectronic components using an optical module with built-in recess or protrusion features, allowing for adjustable positioning and improved coupling efficiency, facilitated by precise lithographic control of mating features and alignment structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional alignment methods are used, then manufacturing precision can be achieved, but productivity is reduced due to time-consuming manual alignment processes
Solution Approach 1:
The patent implements preliminary action by pre-forming alignment features (protrusions or recesses) on the substrate during the substrate fabrication process using lithography. These features are prepared in advance to automatically guide the positioning of optical components, eliminating the need for time-consuming manual alignment during assembly while maintaining high precision.
Solution Approach 2:
The alignment features enable self-service alignment where the optical component automatically positions itself relative to the substrate through the mating protrusion-recess geometry. The component's own structure interacts with the pre-formed features to achieve precise alignment without external intervention or complex alignment mechanisms.
2Ease of manufacture
If assembly machines with improper placement tolerance are used to reduce costs, then manufacturing cost decreases, but manufacturing precision deteriorates
Solution Approach 1:
The alignment features enable self-service alignment where the optical component automatically positions itself relative to the substrate through the mating protrusion-recess geometry. This self-aligning mechanism compensates for the imprecise placement capability of low-cost assembly machines, allowing inexpensive equipment to achieve high precision results without requiring sophisticated placement control.
Solution Approach 2:
The alignment features utilize asymmetric protrusion-recess geometry that provides directional guidance and constraint. The asymmetric shape ensures that the optical component can only be positioned in the correct orientation and location, preventing misplacement even when using equipment with poor placement tolerance. The asymmetric design inherently guides the component into the proper position during the assembly process.
Data Source
AI summary
A system, optical assembly, and optical communication system are disclosed. The optical assembly is disclosed as including an optoelectronic component having a predetermined shape and an optical module that permits light emitted by the optoelectronic component or travelling to the optoelectronic component to pass therethough. The optical module is further disclosed as including a first surface and an opposing second surface, the first surface of the optical module including a first mating feature to receive the optoelectronic component, and the second surface of the optical module including a receptacle to receive and align an optical fiber with the optoelectronic component.