Optical Subassembly Alignment via UV Adhesive and Lens-Mirror Integration
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Solution Overview
Problem
Existing optical modules face challenges in downsizing and cost reduction due to fixed component positions, which hinder the absorption of component tolerances, and active alignment methods increase manufacturing costs.
Innovation Solution
The optical subassembly combines passive and active alignment techniques, using a lens element and supporting element made of different materials with specific transmittance properties, integrated with a substrate and adhesion layer, allowing for easy adjustment of positioning through UV curable adhesive and alignment marks, enabling stable optical coupling while reducing manufacturing complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If passive alignment is used to mount components, then manufacturing cost is reduced, but optical coupling characteristics become unstable due to fixed component positions that cannot absorb tolerances
Solution Approach 1:
The patent divides the alignment process into two distinct phases: passive alignment for initial component placement (reducing cost) and active alignment for final optical axis adjustment (ensuring performance). This segmentation allows each method to be applied where it is most effective, resolving the contradiction between cost and reliability.
Solution Approach 2:
The patent introduces adjustable positioning structures that allow component positions to be modified after initial mounting. The optical element and lens element can be dynamically adjusted along the optical axis and laterally to achieve optimal alignment, transforming the fixed positioning of passive alignment into a dynamic system that can absorb tolerances.
2Reliability
If active alignment is used during optical axis adjustment, then stable high optical coupling characteristics are achieved, but manufacturing cost increases due to more steps and complexities
Solution Approach 1:
The patent performs preliminary passive alignment to establish approximate component positions before final active alignment. This preliminary action reduces the adjustment range required in the subsequent active alignment step, simplifying the overall process and reducing costs while maintaining high optical coupling characteristics.
Solution Approach 2:
The patent uses alignment marks and positioning structures as intermediaries between the passive and active alignment processes. These intermediaries provide reference points that guide the active alignment process, making it simpler and less costly by reducing the complexity of direct optical alignment.
3Device complexity
If component positions are fixed to simplify assembly, then manufacturing process is simplified, but tolerance absorption is impeded
Solution Approach 1:
The patent implements dynamic positioning mechanisms that allow components to be adjusted after assembly. The optical element can be moved along the optical axis and laterally, and the lens element can be repositioned, enabling tolerance absorption without complicating the initial assembly process. The fixed positions during assembly are temporary, followed by a simple adjustment step.
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 enables easy adjustment of optical components, achieving stable high optical coupling characteristics and reducing manufacturing costs, while allowing for downsizing of optical subassemblies and modules.
Implementation Method 1
UV curable adhesive
Implementation Method 2
lens element with a lens and a mirror integrated
Implementation Method 3
lens element with a lens and a mirror integrated
Data Source
AI summary
An optical subassembly may have an optical waveguide for transmitting an optical signal, a lens element with a lens and a mirror integrated, a supporting element to which the optical waveguide and the lens element are attached, an optical element for converting the optical signal and an electric signal from one to another at least, and a substrate to which the optical element and the supporting element are attached.