Optical Module Alignment Using Fixed Camera Focal Point
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Solution Overview
Problem
Existing optical module alignment techniques suffer from reduced precision due to the need to move cameras and adjust focal points, leading to potential displacement and inclination, which complicates the alignment of optical fibers and devices, especially when dealing with different wavelengths of light.
Innovation Solution
The method involves using a camera with its focal point adjusted to the optical fiber coupling plane, allowing simultaneous observation of the resin member and optical device active layer, eliminating the need for focal point adjustments and preventing camera inclination, thereby enhancing position precision by maintaining aligned relative positions during the alignment process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the camera is moved to adjust the focal point for different wavelengths of light, then the position alignment can be performed, but the position precision deteriorates due to camera inclination and displacement
Solution Approach 1:
The patent applies preliminary action by pre-positioning the camera at a fixed location and pre-setting the focal point to the optical fiber coupling plane before the alignment process. This eliminates the need for camera movement during alignment, thereby maintaining position precision while simplifying the overall alignment operation. The camera remains stationary throughout the process, and the focal point is adjusted in advance to match the coupling plane position.
2Adaptability or versatility
If the focal point of the camera is adjusted during position alignment, then different wavelengths can be accommodated, but the relative positions of the resin member and optical device may be displaced
Solution Approach 1:
The patent employs the copying principle by using the optical device active layer as a reference copy that emits light at a specific wavelength. The lens is designed to focus this light at the optical fiber coupling plane, creating a stable reference image. By fixing the camera focal point at this coupling plane, the system maintains consistent reference across different alignment operations without requiring focal adjustment, thereby preserving manufacturing precision while remaining adaptable to different wavelengths through the optical device's inherent properties.
3Measurement precision
If the camera is repositioned to maintain focal point accuracy, then the observation quality improves, but the alignment process becomes more complex and time-consuming
Solution Approach 1:
The patent applies preliminary action by pre-positioning the camera at a fixed location and pre-setting the focal point to the optical fiber coupling plane before the alignment process. This eliminates the need for camera movement during alignment, thereby maintaining position precision while simplifying the overall alignment operation. The camera remains stationary throughout the process, and the focal point is adjusted in advance to match the coupling plane position.
Solution Approach 2:
The system implements self-service by using the optical device active layer itself to provide the reference signal for alignment. The active layer emits light that naturally focuses at the coupling plane through the lens, creating a self-aligning reference that eliminates the need for external adjustment mechanisms. This self-service approach maintains observation precision while significantly improving alignment efficiency by removing the need for continuous camera repositioning.
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 approach improves the precision of optical fiber and device alignment, simplifies the alignment process, and reduces manufacturing costs by eliminating the need for dedicated structures and complex alignment operations.
Implementation Method 1
a lens configured to focus the invisible light on the optical fiber coupling plane
Implementation Method 2
The refractive index of the light depends on the wavelength thereof. Thus, after transmitted through the lens, light having a different wavelength is focused on a different plane
Implementation Method 3
observing the resin member located at the optical fiber coupling plane and the optical device active layer whose image is formed at the optical fiber coupling plane, with use of a camera
Data Source
AI summary
A method of manufacturing an optical module includes the steps of applying the invisible light onto the resin member and the optical device, observing, with use of a camera, a part of the resin member located at the optical fiber coupling plane and an image formed at the optical fiber coupling plane by the optical device active layer while applying the invisible light onto the resin member and the optical device, aligning positions of the resin member and the circuit board with respect to each other while observing the part of the resin member located at the optical fiber coupling plane and the image formed at the optical fiber coupling plane, and fixing the resin member to the circuit board while maintaining the aligned positions of the resin member and the circuit board.