Optical Module Lens Sheet Alignment Marks
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Solution Overview
Problem
Conventional optical interconnect modules experience significant coupling loss due to mismatched apertures between light-emitting/receiving elements and optical waveguides, especially at high speeds, leading to inefficiencies in high-speed optical transmission beyond 20 GBps.
Innovation Solution
An optical module design featuring a lens sheet with a light-collecting lens and alignment marks, integrated with a flexible printed circuit board and a polymer waveguide, ensures precise alignment and efficient optical coupling by using a Fresnel lens for improved light concentration and reduced thickness, thereby minimizing coupling loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the aperture of the light receiving surface is made smaller to reduce stray capacity for high-speed operation, then the light-receiving element can operate at higher speeds (20 GBps or more), but the coupling loss between the light-receiving element and the optical waveguide increases
Solution Approach 1:
A lens is introduced as an intermediary component between the light-receiving element and the optical waveguide. The lens collects and focuses the light beams from the optical waveguide onto the light-receiving element, enabling efficient coupling even when the light-receiving element has a small aperture for high-speed operation.
Solution Approach 2:
The invention changes the optical parameters by introducing a lens with specific focal length and aperture characteristics. This allows the system to maintain high-speed operation (small aperture) while compensating for coupling loss through the lens's light-concentrating capability.
2Loss of energy
If a microlens is formed on the light receiving surface using a dispenser to integrally form a light-receiving element and a lens, then coupling efficiency improves, but the manufacturing complexity and cost increase
Solution Approach 1:
Instead of integrally forming the light-receiving element and lens using complex dispenser processes, the invention separates these components. The lens is formed as a distinct component on the circuit board, and the light-receiving element is mounted separately, simplifying the manufacturing process while maintaining coupling efficiency.
Solution Approach 2:
The lens serves as a separate intermediary component between the optical waveguide and the light-receiving element, allowing each component to be manufactured independently using simpler processes while still achieving efficient optical coupling.
3Speed
If the substrate is thickened to respond to high frequencies for light-emitting elements, then high-frequency response is improved, but some emitting beams have difficulty coupling with the optical waveguide, leading to optical loss
Solution Approach 1:
A lens is introduced as an intermediary component between the light-emitting element and the optical waveguide. The lens collects and directs the emitting beams onto the optical waveguide, enabling efficient coupling even when the substrate is thickened for high-frequency response.
4Adaptability or versatility
If the aperture of the light-emitting part or light-receiving part does not match the input/output aperture of the optical waveguide, then the optical element can be designed for specific performance requirements, but signal light beams are emitted outside, increasing coupling loss
Solution Approach 1:
The lens acts as an intermediary that bridges the aperture mismatch between the optical element and the optical waveguide. It collects and focuses the light beams, directing them onto the waveguide aperture, thereby maintaining design flexibility while minimizing coupling loss.
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 significantly enhances optical coupling efficiency, enabling high-speed transmission beyond 20 GBps with reduced manufacturing costs and improved alignment precision, effectively addressing the aperture mismatch issue.
Implementation Method 1
a lens formed on a part of the lens sheet, where light from the optical element passes through the part of the lens sheet
Implementation Method 2
using a Fresnel lens for improved light concentration and reduced thickness
Data Source
AI summary
A an optical module includes a circuit board provided with an optical element selected from a light-receiving element and/or a light-emitting element; a lens where light from the optical element passes through; an alignment mark serving as an indicator for alignment with the optical element; and an optical waveguide formed to input/output light into/from the optical element through the lens.