Optical Module Alignment via Segmented Ferrule Subassemblies
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Solution Overview
Problem
Current optical modules with multiple optical subassemblies require lengthy assembly times and increased costs due to complex alignment processes, hindering high-density packaging and reducing alignment accuracy.
Innovation Solution
The optical module design includes first and second optical element sections with ferrules and optical systems, allowing independent alignment of each section, using ferrules and wavelength multiplexing optical elements to simplify the alignment process and reduce assembly time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple optical subassemblies are used in the optical module, then high-density packaging and wavelength multiplexing capability are improved, but alignment complexity and assembly time increase significantly
Solution Approach 1:
The optical module is divided into multiple independent optical subassemblies, each handling a specific wavelength channel. Each subassembly contains its own optical components (laser diode, collimator lens, filter, mirror) that can be aligned and tested independently before integration into the final module. This segmentation allows parallel processing and reduces the overall alignment complexity.
Solution Approach 2:
Optical alignment is performed during the subassembly manufacturing stage rather than during final module assembly. The ferrules are pre-aligned with the optical components and fixed in position, creating self-aligning subassemblies. This preliminary alignment action eliminates the need for complex alignment procedures during module assembly, significantly reducing assembly time and complexity.
2Manufacturing precision
If traditional alignment methods are used for multiple optical subassemblies, then alignment accuracy can be maintained, but assembly time and cost increase
Solution Approach 1:
The ferrule design provides self-aligning functionality through its geometric features. The ferrule contains a positioning protrusion that fits into a corresponding positioning groove in the subassembly base, automatically establishing the correct positional relationship between the ferrule and optical components without requiring manual adjustment or complex alignment equipment.
Solution Approach 2:
The invention changes the alignment parameter from angular/positional adjustment to dimensional tolerance control. By designing the ferrule and subassembly base with precise dimensional tolerances and self-aligning geometric features, the alignment accuracy is achieved through manufacturing precision rather than assembly adjustment, significantly reducing assembly time.
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 enables easy alignment of optical modules, simplifies the manufacturing process, reduces assembly time, and lowers costs while maintaining high alignment accuracy and density, allowing for efficient use in high-channel count applications like WDM systems.
Implementation Method 1
an optical conversion element that converts one of an optical signal and an electric signal into the other
Implementation Method 2
a ferrule, having a distal end being in contact with and optically joined to the second optical element section
Implementation Method 3
a wavelength multiplexing optical element optically joined to the optical conversion elements of the plurality of first optical element sections
Data Source
AI summary
To provide an optical module and a method for aligning the optical module with which alignment can be easily performed. An optical module includes first optical element sections and a second optical element section optically joined to the first optical element sections. Each first optical element section includes an optical conversion element, a ferrule having a distal end being in contact with and optically joined to the second optical element section, and a first optical system disposed in a position where the ferrule and the optical conversion element are optically adjusted. The second optical element section includes joining sections in contact with and joined to, in joining parts, the distal ends of the ferrules, a wavelength multiplexing optical element optically joined to the optical conversion elements, and second optical systems respectively disposed in positions where the wavelength multiplexing optical elements and the joining parts are optically adjusted.