Optical Subassembly Holder for Stress-Resilient Alignment
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Solution Overview
Problem
Optoelectronic modules face significant optical misalignment issues due to external forces and thermal stresses during assembly, leading to substantial optical power loss as data rates increase from 10G to 25G and 50G, with traditional securing methods like fasteners and adhesives inducing mechanical stresses that cause misalignment.
Innovation Solution
The use of a sacrificial spacer (holder) detachably coupled to the optical port block with uncured epoxy during assembly, allowing the OSA and optical port block to move as a single unit, reducing stress-induced misalignment by exerting balanced forces, and subsequently fixing the holder to the housing once assembled, ensuring optical alignment is maintained.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional fasteners or adhesives are used to secure the OSA inside the module, then the OSA is firmly fixed, but mechanical stresses are induced causing optical misalignment
Solution Approach 1:
The holder is divided into two functional segments: a first end that detachably couples to the optical port block and a second end that fixedly couples to the housing. This segmentation allows the holder to provide structural support while avoiding continuous stress transmission to the OSA, resolving the contradiction between fixing strength and optical alignment precision.
Solution Approach 2:
The holder acts as an intermediary component between the housing and the optical port block/OSA assembly. By introducing this intermediate element, the design decouples the structural mounting function from the optical alignment function, allowing the OSA to be secured without direct mechanical stress from the housing, thus maintaining both fixing strength and optical alignment.
2Stability of the object's composition
If the OSA is firmly secured during assembly, then positioning stability is achieved, but stress-induced misalignment occurs
Solution Approach 1:
The holder is pre-positioned and detachably coupled to the optical port block before final assembly into the housing. This preliminary action allows the OSA assembly to be positioned and stabilized without the constraints of the final housing mounting, preventing stress-induced misalignment while maintaining positioning stability during the assembly process.
Solution Approach 2:
The coupling between the holder and optical port block is designed to be detachable rather than permanent, introducing dynamic flexibility to the system. This allows the assembly to accommodate dimensional variations and stress changes during assembly without inducing misalignment, while still providing sufficient positioning stability.
3Strength
If the holder is fixedly coupled during assembly, then structural support is provided, but the OSA cannot be removed for reworking
Solution Approach 1:
The holder is segmented into a detachably coupled first end and a fixedly coupled second end. This segmentation enables the first end to be removed for component reworking while the second end remains fixed to provide continuous structural support to the housing, resolving the contradiction between structural support and repairability.
Solution Approach 2:
The detachable coupling at the first end of the holder allows the optical port block and OSA to be recovered and removed for reworking or replacement, while the second end remains permanently fixed to maintain structural integrity. This selective permanence enables both structural support and ease of repair.
4Reliability
If the OSA is securely mounted, then assembly stability is achieved, but optical power loss increases due to misalignment
Solution Approach 1:
The holder serves as an intermediary that provides assembly stability through its fixed coupling to the housing, while its detachable coupling to the optical port block prevents stress transmission that would cause misalignment. This intermediary function maintains both assembly stability and optical power efficiency by decoupling the stability-providing function from the alignment-affecting function.
Solution Approach 2:
By segmenting the holder into fixed and detachable portions, the design achieves assembly stability through the fixed second end while preventing misalignment through the detachable first end, thereby maintaining optical power efficiency without sacrificing assembly 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 effectively reduces stress-induced misalignment, minimizing optical power loss and facilitating the reworking and salvaging of components without damage, enhancing the reliability and performance of optoelectronic modules at higher data rates.
Implementation Method 1
The holder may be fixedly coupled to the housing after assembly of the optoelectronic module and may be floatably coupled to the housing during assembly of the optoelectronic module. The holder may be fixedly coupled to the housing after assembly by cured epoxy and may be floatably coupled to the housing during assembly by uncured epoxy.
Implementation Method 2
The holder may be fixedly coupled to the housing after assembly by cured epoxy
Data Source
AI summary
An example optoelectronic module may include an optical subassembly (OSA), an optical port block, a housing, and a holder. The OSA may be configured to convert between optical and electrical signals. The optical port block may be attached to the OSA and may be configured to optically align a fiber optic cable with the OSA. The housing may be configured to substantially enclose the OSA and the optical port block. The holder may be configured to couple the OSA and the optical port block to the housing. The holder may be detachably coupled to the optical port block and fixedly coupled to the housing.