Optical Module Ferrule Alignment for PCB Integration
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Solution Overview
Problem
Existing optical printed circuit boards (PCBs) face challenges in precisely aligning optical waveguides with optical connection rods or blocks, requiring complex stacking and drilling processes, which complicates the manufacturing and alignment of optical components.
Innovation Solution
The use of first and second ferrules coupled to both ends of an optical fiber, supported by a first and second board, allows for simplified alignment and integration of optical transmitter and receiver modules, with the optical fiber extending between them, facilitating precise alignment and a streamlined manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If optical waveguides are buried in the PCB with multiple layers stacked and drilling processes performed, then the ability to mount components increases, but the alignment precision between optical waveguides and optical connection rods/blocks deteriorates
Solution Approach 1:
The patent introduces an optical connection block as an intermediary component that bridges the optical waveguide and the optical connection rod. This intermediary structure simplifies the alignment process by providing a standardized interface, eliminating the need for precise manual alignment between the waveguide and the rod while maintaining component mounting capability through the multi-layer PCB structure.
Solution Approach 2:
The patent divides the optical connection system into separate functional modules: optical waveguides embedded in the PCB, optical connection blocks as intermediate components, and optical connection rods as terminal elements. This segmentation allows each component to be manufactured and positioned independently, improving overall alignment precision while maintaining the ability to mount multiple components through the multi-layer structure.
2Adaptability or versatility
If multiple layers are stacked and drilling processes are performed to insert optical waveguides, then more components can be mounted, but the manufacturing complexity increases
Solution Approach 1:
The patent merges the optical connection block functionality directly into the PCB structure, eliminating the need for separate drilling and insertion processes. The optical connection blocks are integrated as part of the multi-layer PCB assembly, allowing multiple components to be mounted simultaneously while simplifying the manufacturing process by combining what were previously separate steps into a unified assembly operation.
3Reliability
If optical connection rods with inclined reflection mirrors or bent glass fibers are inserted into optical via holes, then optical signals can be transmitted, but the alignment difficulty increases
Solution Approach 1:
The optical connection block serves as a mediator that receives the optical waveguide and connects it to the optical connection rod with standardized interfaces. This intermediary structure handles the alignment complexity internally, providing reliable optical signal transmission while presenting simple alignment requirements to the operator, thus improving ease of operation without compromising transmission reliability.
Data Source
AI summary
Provided are an optical module, and an optical printed circuit board and a method of manufacturing the same. The optical module includes an optical fiber, a first ferrule coupled to one end of the optical fiber, and a second ferrule coupled to the other end of the optical fiber. The optical printed circuit board includes a first board, an optical transmitter module and an optical receiver module, which are disposed on the first board, an optical fiber passing through the first board, the optical fiber extending integrally from a lower side of the optical transmitter module to a lower side of the optical receiver module, first and second ferrules coupled to one end and the other end of the optical fiber, respectively, the first and second ferrules being supported by the first board, and a second board through which the optical fiber passes, the second board being disposed below the first board.