Optical Sub-Assembly Cap With Integrated Lens For Alignment
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Solution Overview
Problem
Conventional optical sub-assembly modules face challenges in production yield due to misalignment of glass lenses and components, requiring multiple alignment operations and resulting in long assembly times and low efficiency.
Innovation Solution
The optical sub-assembly module incorporates a cap with a receiving groove, longitudinal groove, and pillar structures, allowing for a single positioning operation between the cap and light emitting component, ensuring accurate alignment and reducing assembly time through an integrally formed lens structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple alignment operations are performed to ensure glass lens and component alignment, then manufacturing precision is improved, but assembly time increases and productivity decreases
Solution Approach 1:
The cap is pre-formed with an integrally formed lens structure that includes positioning features (such as positioning grooves or protrusions) that automatically align the light emitting component during a single assembly operation. This preliminary preparation of alignment features in the cap eliminates the need for subsequent manual alignment operations, thereby maintaining precision while improving productivity
Solution Approach 2:
The lens structure and positioning features are merged into a single integrally formed component within the cap. This integration ensures that the alignment features are precisely formed relative to the lens structure, eliminating cumulative errors from separate manufacturing steps and enabling accurate alignment in a single assembly operation
2Manufacturing precision
If multiple alignment operations are performed to ensure glass lens and component alignment, then manufacturing precision is improved, but assembly time increases
Solution Approach 1:
The cap is pre-formed with an integrally formed lens structure that includes positioning features (such as positioning grooves or protrusions) that automatically align the light emitting component during a single assembly operation. This preliminary preparation of alignment features in the cap eliminates the need for subsequent manual alignment operations, thereby maintaining precision while improving productivity
Solution Approach 2:
The alignment function is segmented from the manual adjustment process and embedded into the cap structure itself through the integrally formed lens structure with built-in positioning features. This segmentation transfers the alignment function from an operational step to a structural feature, eliminating time loss while maintaining precision
Data Source
AI summary
An optical sub-assembly module and a cap thereof are provided. Two opposite ends of the cap are respectively defined as a light source end and a connecting end. The cap includes a receiving groove, a longitudinal groove, a lens structure and a plurality of pillar structures. The receiving groove is recessed inwardly from the light source end. The longitudinal groove is recessed inwardly from the connecting end. The lens structure is integrally formed with the cap, the lens structure is located between the receiving groove and the longitudinal groove, and the lens structure blocks spatial communication between the receiving groove and the longitudinal groove. Each of the pillar structures is connected to an inner wall that surrounds the receiving groove.