Optical Module Substrate Cavity Layout for Clean Light Paths
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Solution Overview
Problem
Existing optical modules face challenges in achieving a thinner design while maintaining effective light transmission and improved mountability of optical coupling modules due to glass threads protruding into cavities, which obstruct accommodation and disrupt light paths.
Innovation Solution
The optical module incorporates a substrate with a glass cloth structure of inclined weft and warp threads, featuring a cavity with inclined side surfaces to accommodate the optical coupling module, reducing glass thread protrusion and enhancing mountability and light transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a cavity is formed in the substrate to accommodate the optical coupling module, then the optical module can be made thinner, but glass threads protrude into the cavity obstructing accommodation and disrupting light paths
Solution Approach 1:
The glass cloth structure is designed with different orientations in different regions: the weft threads run substantially parallel to the first pair of side surfaces while the warp threads run substantially parallel to the second pair of side surfaces. This local orientation arrangement ensures that when a cavity is formed, glass threads do not protrude into the cavity space, eliminating obstruction to optical coupling module accommodation and preventing light path disruption while maintaining the thin profile of the optical module
Solution Approach 2:
The glass cloth is pre-oriented with weft and warp threads aligned parallel to the respective side surfaces before the cavity is formed. This preliminary orientation prevents glass thread protrusion into the cavity space, eliminating the need for post-processing to remove protruding threads and ensuring clean cavity surfaces for optical coupling module installation
2Strength
If glass cloth is used in the substrate, then substrate strength is maintained, but glass threads may protrude into the cavity and disrupt light transmission
Solution Approach 1:
The glass cloth is configured with weft threads substantially parallel to the first pair of side surfaces and warp threads substantially parallel to the second pair of side surfaces. This local orientation arrangement prevents glass thread protrusion into the cavity, maintaining both substrate strength from the glass cloth structure and light transmission quality by eliminating thread interference in the optical path
Solution Approach 2:
The substrate is constructed as a composite material combining glass cloth reinforcement with a resin matrix. The glass cloth provides mechanical strength while the resin matrix binds the glass threads and prevents them from protruding into the cavity, thus maintaining both substrate strength and light transmission reliability
Data Source
AI summary
An optical module includes a substrate, an optical element, and an optical coupling module. The substrate includes a glass cloth constituted of glass threads serving as weft and warp. An outer edge of the substrate has a rectangular shape defined by a pair of first side surfaces in a predetermined direction and a pair of second side surfaces in a direction orthogonal to the predetermined direction. The weft is inclined with respect to the first side surfaces and the second side surfaces. The warp is inclined with respect to the first side surfaces and the second side surfaces. A cavity is formed in the substrate. At least a part of the optical coupling module is accommodated in the cavity. A side surface of the cavity includes an inclined region inclined with respect to an extension direction of the weft and an extension direction of the warp.