Optical Module Base Plate Warping Mitigation
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Solution Overview
Problem
Existing optical modules face challenges in maintaining precise alignment of multiplexed light beams due to thermal expansion, leading to displacement of optical axes and reduced image quality and coupling efficiency across varying temperatures.
Innovation Solution
The optical module design includes a base plate with a gap between the filter mounting region and the support base, notches, and varying thicknesses in different regions to minimize warping, along with the use of semiconductor lasers and an electronic cooling module to maintain precise alignment of optical axes across a wide temperature range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the base plate is rigidly mounted to the support base, then structural stability is improved, but thermal expansion causes warping and displacement of optical axes
Solution Approach 1:
The base plate is divided into multiple regions with different thicknesses (first, second, and third thicknesses) corresponding to different functional areas. This segmentation allows each region to independently manage thermal expansion, preventing overall warping while maintaining structural stability.
Solution Approach 2:
Different regions of the base plate are given different local properties through varying thickness. The first region has a first thickness, the second region has a second thickness, and the third region has a third thickness, allowing each area to respond differently to thermal stress and maintain precise optical alignment.
2Ease of manufacture
If the base plate thickness is uniform, then manufacturing is simplified, but thermal expansion causes warping and optical axis displacement
Solution Approach 1:
The base plate features non-uniform thickness distribution with at least three different thickness regions. This local variation in geometry provides dimensional stability under thermal expansion while remaining manufacturable through standard precision machining or molding processes.
3Adaptability or versatility
If the optical module operates across a wide temperature range, then environmental adaptability is improved, but thermal expansion causes misalignment and reduced image quality
Solution Approach 1:
The base plate geometry is designed with varying thickness parameters to compensate for thermal expansion effects across a wide temperature range. This parameter optimization allows the optical module to maintain precise alignment from -40°C to +85°C despite dimensional changes in the materials.
4Weight of moving object
If the base plate is thin and lightweight, then device weight is reduced, but structural rigidity decreases leading to increased warping
Solution Approach 1:
The base plate uses localized thickness variation to achieve optimal rigidity only where needed. Critical areas have increased thickness for structural support, while other areas remain thin to minimize weight, creating an efficient weight-to-strength ratio that prevents warping without excessive mass.
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 ensures high-precision alignment of multiplexed light beams at various temperatures, maintaining image quality and coupling efficiency, even at extreme temperatures, by reducing warping and displacement of optical axes.
Implementation Method 1
a first lens that transforms the first light emitted from the first emitting portion into a collimated beam
Implementation Method 2
a second lens that transforms the second light emitted from the second emitting portion into a collimated beam
Implementation Method 3
a filter that multiplexes the first light and the second light
Implementation Method 4
Existing optical modules face challenges in maintaining precise alignment of multiplexed light beams due to thermal expansion
Data Source
AI summary
An optical module includes a first semiconductor light-emitting element, a second semiconductor light-emitting element, a first lens, a second lens, a filter that multiplexes the first light and the second light, a base plate that has a first surface on which the first semiconductor light-emitting element, the second semiconductor light-emitting element, the first lens, the second lens, and the filter are mounted and a second surface opposite the first surface in a thickness direction, and a support base that is in contact with a part of the second surface and that supports the base plate. The base plate has a filter mounting region in which the filter is mounted. The optical module has a gap between a region of the second surface corresponding to the filter mounting region and the support base.