Optical Communication Module Transparent Resin Alignment
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Solution Overview
Problem
Conventional optical communication modules face challenges with high complexity, cost, and accuracy issues due to the need for multiple parts and complex manufacturing procedures, as well as positional mis-adjustment of photoelectric devices and optical fibers, which affect communication performance.
Innovation Solution
A method for manufacturing an optical communication module that integrates a photoelectric device with a synthetic resin part, a lens part, and a cylindrical part, using transparent synthetic resin and image recognition positional adjustment to simplify the module's structure and improve alignment accuracy, reducing the number of parts and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple parts (stem, cap, heat sink, submount plate) are used to support the photoelectric device, then the structural stability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent integrates multiple support functions into a single stem structure. The stem simultaneously provides mechanical support, positioning, and thermal management for the photoelectric device, eliminating the need for separate heat sinks and submount plates. This merging reduces part count and simplifies manufacturing while maintaining structural stability.
Solution Approach 2:
The stem is designed as a multi-functional component that performs multiple roles: mechanical support, precise positioning of the photoelectric device, and thermal conduction. This universal design consolidates functions previously requiring separate components, reducing overall device complexity.
2Ease of manufacture
If positional adjustment is performed manually for the photoelectric device and optical fiber, then the manufacturing cost is reduced, but the alignment accuracy deteriorates
Solution Approach 1:
The stem incorporates pre-formed positioning structures and alignment features that guide the photoelectric device and optical fiber into correct positions during assembly. This preliminary preparation of alignment features enables accurate positioning without requiring complex manual adjustment procedures during manufacturing.
Solution Approach 2:
The patent replaces manual mechanical adjustment with a standardized assembly process using precision-machined positioning features on the stem. The mechanical tolerance of these features ensures consistent alignment accuracy across production batches, eliminating variability associated with manual adjustment.
3Measurement precision
If the synthetic resin part is made transparent, then the image recognition for positional adjustment is improved, but the mechanical strength may be reduced
Solution Approach 1:
The patent selects transparent synthetic resin materials with optimized optical and mechanical properties. By adjusting material parameters such as transparency, tensile strength, and thermal conductivity, the resin part achieves both the required optical clarity for image recognition and sufficient mechanical strength for structural support.
Solution Approach 2:
The use of engineered transparent synthetic resin creates a composite material that combines optical transparency with enhanced mechanical properties. This composite material simultaneously enables image recognition through the part while maintaining the structural integrity required for supporting the photoelectric device.
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 reduces the number of parts required, simplifies the manufacturing process, and enhances the accuracy of optical signal transmission and reception by ensuring precise alignment of the photoelectric device with the optical axis and optical fiber, thereby improving communication performance and reducing costs.
Implementation Method 1
utilizing a camera to capture the lens part formed integrally during the first step through the synthetic resin part which is transparent
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
It is expected to provide an optical communication module and a method for manufacturing the optical communication module that can prevent worsening of communication performance caused by the positional mis-adjustment of a light emitting or receiving portion of a photoelectric device, a lens, an optical fiber and the like, and can facilitate the manufacturing procedure. In the OSA 1, the base part 10 mounting the photodiode 25, the lens part 40 and the cylindrical part 50 are connected and fixed. In order to perform the positional adjustment for the center of the light receiving portion of the photodiode 25 mounted on the base part 10 and the center of the lens part 40, an image recognition positional adjustment is performed in accordance with an image captured from the upper side of the base part by the camera 7. Or, the positional adjustment for the center of the lens part 40 and the center of the cylindrical part 50 is performed in accordance with an image captured from the upper side of the lens part 40 by the camera.