Optical Transmission Module Refraction Alignment
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Solution Overview
Problem
Existing methods for manufacturing optical transmission modules require complex operations involving three-dimensional movement and rotation of components to optically couple optical cables and photoelectric conversion elements, making the process cumbersome and inefficient.
Innovation Solution
A method that involves temporarily disposing a receptacle with a lens over a mounting substrate, aligning it based on the position of a light spot and the designed intersection point of the optical axis, and sliding it into position without rotating the receptacle, utilizing refraction to achieve optical coupling between the photoelectric conversion element and the optical cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If three-dimensional movement and rotation of components are used to optically couple optical cable and photoelectric conversion element, then optical coupling is achieved, but the operation process becomes complicated
Solution Approach 1:
The patent replaces the mechanical rotation operation with an optical refraction mechanism. The lens inside the receptacle refracts light to change the optical axis direction, allowing optical coupling to be achieved through linear movement only, thereby eliminating the need for complex rotational mechanical operations.
Solution Approach 2:
The lens acts as an intermediary element between the photoelectric conversion element and the optical cable. It mediates the optical path by refracting light, enabling the optical axes to be coupled through simple linear displacement of the receptacle rather than through direct alignment requiring rotation.
2Ease of operation
If lens is used to refract light and change optical axis direction, then component movement is simplified to linear motion only, but manufacturing precision requirements increase
Solution Approach 1:
The system uses the light spot position detection method where the emitted light itself serves as the reference for positioning. By detecting where the light spot falls on the optical cable, the system automatically provides feedback for precise positioning of the lens and receptacle, eliminating the need for external complex alignment tools.
Solution Approach 2:
The patent replaces complex mechanical rotation and multi-axis positioning mechanisms with a simpler linear movement system guided by optical feedback. The refraction mechanism combined with light spot detection creates a self-aligning system that reduces manufacturing precision requirements compared to direct mechanical alignment methods.
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
Facilitates easier and more accurate optical coupling with reduced optical loss, simplifying the manufacturing process and reducing the complexity of component alignment, while maintaining a low module thickness.
Implementation Method 1
light from the photoelectric conversion element passes through the lens. Accordingly, the light from the photoelectric conversion element is refracted by the lens, and thus the direction of its optical axis changes
Data Source
AI summary
A method of manufacturing an optical transmission module includes temporary disposing, measuring, and placing steps. The temporary disposing step includes temporarily disposing a light-emitting-element receptacle over a mounting substrate so that a lens of the light-emitting-element receptacle and a light emitting element array face each other. The measuring step includes measuring the position of a light spot at which light emitted from the light-emitting element array emerges from the emergence surface of the light-emitting-element receptacle. The placing step includes placing the light-emitting-element receptacle over the mounting substrate on the basis of information on the position of a designed intersection point of the optical axis of an optical cable with the emergence surface of the light-emitting-element receptacle, and information on the position of the light spot.