Optical Module Passive Alignment via Intermediate Layers
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Solution Overview
Problem
Current optical modules face challenges in achieving high-speed, high-bandwidth, and high-density data transmission with high optical signal integrity, particularly due to issues with optical alignment accuracy, coupling efficiency, and signal noise, which complicates mass production and increases costs due to the need for expensive precision equipment and instruments.
Innovation Solution
The development of an optical module using a complete passive alignment method with an optical coupling wire and intermediate layers to connect photonic devices, optimizing physical, mechanical, thermal, and optical properties for improved signal transmission and reception without requiring expensive precision equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If active optical alignment method is used, then optical alignment precision is improved, but manufacturing cost and device complexity increase due to expensive high-precision equipment
Solution Approach 1:
The patent introduces an intermediary alignment mark structure that mediates between the transmitter and receiver substrates. This alignment mark serves as a reference that enables passive alignment without requiring complex active alignment equipment, thus resolving the contradiction between alignment precision and equipment complexity
Solution Approach 2:
The alignment mark structure is designed to enable self-alignment during the bonding process. The protrusion and recess geometry automatically guides the relative positioning of transmitter and receiver substrates, eliminating the need for external active alignment equipment while maintaining high alignment precision
2Manufacturing precision
If active optical alignment method is used, then optical alignment precision is improved, but productivity decreases due to complex equipment and processes
Solution Approach 1:
The self-aligning geometry of the alignment mark structure enables automatic positioning during bonding, eliminating time-consuming active alignment procedures. This significantly improves productivity while maintaining alignment precision, making the process suitable for mass production
Solution Approach 2:
The alignment mark structure is pre-formed on the substrates before bonding, establishing the alignment reference in advance. This preliminary action eliminates the need for complex real-time alignment adjustments during assembly, thereby improving manufacturing efficiency
3Reliability
If lens optical system is used, then optical signal transmission is achieved, but optical coupling efficiency decreases due to interface reflections and scattering
Solution Approach 1:
The patent removes the lens components from the optical system, replacing them with direct optical coupling through aligned waveguides. This extraction of lenses eliminates the multiple air-glass interfaces that cause reflection and scattering losses, thereby improving optical coupling efficiency while maintaining signal transmission reliability
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 approach enhances optical coupling efficiency and signal integrity, enabling high-speed, high-density optical modules with improved productivity and yield, facilitating cost-effective mass production while maintaining high performance.
Implementation Method 1
an optical coupling wire comprising a first end formed with a predetermined first shape and first material in contact with the first transmitting surface, a second end formed with a predetermined second shape and second material in contact with the second photonic device
Implementation Method 2
a first intermediate layer comprising a first receiving surface receiving an optical signal delivered from the first photonic device and a first transmitting surface transmitting an optical signal to the outside
Implementation Method 3
formed with a material having at least one of predetermined physical, mechanical, thermal, and optical properties
Data Source
AI summary
Disclosed is an optical module that improves optical coupling efficiency. Embodiments of the present invention provide an optical module including a first photonic device comprising a first emitting surface emitting an optical signal having a predetermined wavelength and intensity; a second photonic device comprising a first incident surface where the optical signal having the predetermined wavelength is incident; and a first intermediate layer comprising a first receiving surface receiving an optical signal delivered from the first photonic device and a first transmitting surface transmitting an optical signal to the outside and formed with a material having at least one of predetermined physical, mechanical, thermal, and optical properties between the first emitting surface and the first incident surface for transmission of an optical signal passing through the first receiving surface and the first transmitting surface.