Optical Transmission Module Lead Frame Mirror
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Solution Overview
Problem
Existing optical transmission modules are expensive and complex due to the use of silicon optical benches, requiring multiple manufacturing steps and precision issues in resin-based modules, which hinder cost-effectiveness and coupling efficiency.
Innovation Solution
A compact optical transmission module using a metal lead frame with integrated electric wiring and a resin housing, where the lead frame is formed through press work and surface machining to create a slit and reflection mirror, eliminating the need for additional components and steps, and allowing direct mounting of electronic devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a silicon optical bench is used as the base, then heat discharging performance is improved, but manufacturing cost increases and manufacturing complexity increases
Solution Approach 1:
The patent replaces the expensive silicon optical bench with a cost-effective metal plate (such as copper or aluminum) that can be manufactured through simpler processes like press work and surface machining. This substitution maintains functional requirements while significantly reducing material cost and manufacturing complexity.
Solution Approach 2:
The patent changes the material parameter from silicon to metal plate, and modifies the manufacturing process parameters from precision machining and oxidation to press work and surface machining. This allows the same functional requirements (heat dissipation, structural support) to be met with different material and process parameters that are more cost-effective.
2Temperature
If a silicon optical bench is used as the base, then heat discharging performance is improved, but device complexity increases
Solution Approach 1:
The patent replaces the complex multi-step silicon optical bench manufacturing process with a simpler metal plate fabrication process involving press work and surface machining. This reduces the number of manufacturing steps and overall device complexity while maintaining heat dissipation functionality.
Solution Approach 2:
The patent combines multiple functions (base structure, heat dissipation, mounting platform) into a single metal plate component. This integration eliminates the need for separate silicon optical bench components and reduces overall device complexity.
3Ease of manufacture
If metal layers are formed on resin base with etching, then wiring pattern is created, but manufacturing steps increase and cost increases
Solution Approach 1:
The patent replaces the multi-step process of forming metal layers on resin base with etching with a simpler direct formation of wiring patterns and reflection mirrors on the metal plate through press work and surface machining. This eliminates unnecessary intermediate steps and reduces manufacturing complexity.
4Ease of manufacture
If V-groove and reflection face are formed by laser beam irradiation, then optical fiber mounting is enabled, but manufacturing steps increase and cost increases
Solution Approach 1:
The patent replaces the expensive laser beam irradiation process with simpler press work and surface machining to form the V-groove and reflection mirror directly on the metal plate. This maintains the optical fiber mounting functionality while significantly reducing manufacturing steps and cost.
5Ease of manufacture
If resin structure is used for V-groove and reflection face, then manufacturing is simplified, but position precision deteriorates
Solution Approach 1:
The patent replaces the low-precision resin molding process with high-precision press work and surface machining on the metal plate. This enables the formation of the V-groove and reflection mirror with high position precision while maintaining ease of manufacture through standardized metalworking processes.
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 configuration results in a cost-effective and compact module with high coupling efficiency between optical fibers and light projecting/receiving elements, reducing manufacturing complexity and precision issues.
Implementation Method 1
a reflection mirror disposed in opposition to the slit and inside the cavity, the mirror being included in the lead frame and formed therein by bending or surface machining, the mirror reflecting light from the light projecting element to the optical fiber and/or light from the optical fiber to the light receiving element
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
Provided is an inexpensive and compact optical transmission module (10) having high coupling efficiency between an optical fiber (400) and a light projecting element (210) and/or a light receiving element (210). This optical transmission module (10) includes a lead frame (110) including an electric wiring pattern formed therein, a resin housing formed through insert-molding of the lead frame (110), and an electric device mounted on the lead frame (110) and including a light projecting element (210) for photoelectric conversion. The lead frame (110) forms a slit (112) positioning an optical fiber (400) to be coupled and a reflection mirror (116) reflecting and condensing light from the light projecting element (210) to the optical fiber (400). The lead frame is bent out of plane at the end of the slit receiving the fibre and thus forms the mirror.