Optical Module Resin Coupling for Low Light Propagation Loss
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Solution Overview
Problem
Existing optical modules suffer from high light propagation loss due to the reflection of optical signals at interfaces with significant refractive index differences, leading to reduced output efficiency and a complex, costly structure.
Innovation Solution
The use of a light-permeable resin cured material to fill the gap between the optical element and the electric circuit board, ensuring a relative refractive index difference of not greater than 20%, thereby reducing reflections and improving light extraction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a lens is provided between the optical element and the optical waveguide to reduce propagation loss, then light propagation efficiency is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent introduces a light-permeable resin composition as an intermediary material filling the gap between the optical element and the electric circuit board. This resin has a refractive index specifically matched to reduce reflection and improve light extraction efficiency, serving as a mediator that optimizes optical coupling without adding mechanical complexity like lenses would require
Solution Approach 2:
The patent changes the refractive index parameter of the material filling the gap between the optical element and the circuit board. By selecting a light-permeable resin with a refractive index between 1.30 and 1.70 (preferably 1.40-1.65), the optical impedance mismatch is reduced, minimizing reflection loss and improving light extraction efficiency without requiring additional optical components
2Loss of energy
If a lens is provided between the optical element and the optical waveguide to reduce propagation loss, then light propagation efficiency is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive precision optical components (lenses) with a inexpensive light-permeable resin composition that can be easily applied and cured. The resin serves as a cost-effective solution that eliminates the need for precision-machined optical elements, significantly reducing manufacturing cost while maintaining or improving optical performance
Solution Approach 2:
The light-permeable resin acts as a simple intermediary material that can be applied through standard dispensing and curing processes, avoiding the need for complex lens mounting, alignment, and bonding procedures. This intermediary approach simplifies the manufacturing process and reduces overall production cost
3Loss of energy
If a light-permeable resin cured material is used to fill the gap between the optical element and the electric circuit board, then light propagation loss is reduced, but the refractive index matching requirement increases material selection complexity
Solution Approach 1:
The patent specifies a refractive index range (1.30-1.70, preferably 1.40-1.65) for the light-permeable resin to optimize light extraction. This parameter specification guides material selection while allowing flexibility in choosing from multiple resin types that fall within this range, balancing optical performance with material availability and processing characteristics
Solution Approach 2:
The patent employs composite resin formulations that combine light-permeable polymers with refractive index modifiers or fillers to achieve the target refractive index range. This composite approach allows tuning of optical properties while maintaining the resin's light-permeability and adhesion characteristics, providing versatility in material selection
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 simplifies the structure and manufacturing process while significantly reducing light propagation loss, enhancing the output efficiency of the optical module.
Implementation Method 1
a relative refractive index difference between the light-permeable resin cured material and the light-permeable resin substrate is not greater than 20%
Data Source
AI summary
An optical module includes: an electric circuit board E including an electric circuit provided on a light-permeable resin substrate 1; and an optical element 11 joined onto the electric circuit board E. The optical element 11 is joined to the electric circuit board E, with a light-emitting portion (or light-receiving portion) 11a of the optical element 11 facing an electric circuit surface side of the electric circuit board E. A space between the light-emitting portion (or light-receiving portion) 11a of the optical element 11 and the light-permeable resin substrate 1 is filled with a light-permeable resin cured material X. A relative refractive index difference between the light-permeable resin cured material X and the light-permeable resin substrate 1 is not greater than 20%. This reduces the propagation loss of light with a simple structure.