Optical Module Glass Layer Curing to Prevent Voids and Loss
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Solution Overview
Problem
Existing optical connection methods using polysilazane for SiO2 glass in optical modules suffer from large curing shrinkage, leading to air gaps and voids, making uniform optical path filling difficult and prone to dust collection and increased connection loss.
Innovation Solution
An optical module design with a glass layer in the optical connection portion between components, incorporating thin tubes for outside air introduction to facilitate uniform polysilazane curing, preventing voids and dust collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polysilazane is used as a glass precursor to fill the optical connection portion, then the connection resistance to high-energy light is improved, but large curing shrinkage occurs causing air gaps and voids that increase connection loss
Solution Approach 1:
The invention divides the curing process into multiple stages by controlling the introduction of outside air through thin tubes. The curing is segmented spatially (from different directions through multiple tubes) and temporally (controlled progression), allowing the glass precursor to cure uniformly without excessive shrinkage that would create voids.
Solution Approach 2:
The thin tubes are pre-installed in the optical module structure before the glass precursor is applied. These tubes serve as pre-positioned channels for controlled air introduction, enabling systematic management of the curing shrinkage process before the actual curing begins.
2Reliability
If a gap (air gap) is left in the light passing portion to prevent resin deterioration, then the resistance to light-induced deterioration is improved, but dust collection occurs in the gap portion increasing connection loss
Solution Approach 1:
The invention introduces outside air as an intermediary substance through the thin tubes during the curing process. This controlled air introduction acts as a mediator to manage the shrinkage of the glass precursor, ensuring uniform filling of the optical connection portion without creating dust-collecting gaps.
3Productivity
If UV curable resin adhesive is used for bonding fiber blocks to PLCs, then the curing time is reduced to several minutes improving productivity, but the resin absorbs high-energy light and deteriorates
Solution Approach 1:
The invention changes the material parameter from UV curable resin adhesive to glass precursor (such as polysilazane) for the optical connection portion. This parameter change maintains the bonding function while eliminating the light absorption and deterioration problem, as glass does not absorb high-energy light like UV curable resins do.
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
The solution ensures excellent optical connection resistance to high-energy light, maintaining low connection loss and preventing optical axis deviation, even under high power and temperature conditions.
Implementation Method 1
polysilazane has a very large curing shrinkage rate, air gaps and voids are generated by the curing shrinkage
Implementation Method 2
The polysilazane is converted into SiO2 glass by reacting with water
Implementation Method 3
SiO2 glass barely softens even in a high temperature environment in addition to having low photoreactivity and little deterioration due to input/output light
Data Source
AI summary
An optical module includes two components that are optically connected, and includes a glass layer disposed in a region including an optical connection portion between the two components, at least one component includes a thin tube through which outside air is introduced, and an end face of the thin tube is in contact with the glass layer.