Optical Sub-Assembly Self-Aligned Coupling
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Solution Overview
Problem
Existing optical coupling and decoupling devices require active alignment of optical fibers with converters, are bulky, and costly, making them unsuitable for miniaturized applications in home and mobile electronics, with high manufacturing effort and optical losses.
Innovation Solution
A miniaturized and modularized active-optical transmitter/receiver unit using an optical sub-assembly made from optically transparent material, where electro-optical or opto-electrical converters are embedded, allowing precise alignment without ferrules or lenses, and a fiber alignment element for low-cost, high-precision fiber insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If active alignment methods are used to align optical fibers with converters, then alignment precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The optical sub-assembly performs self-alignment through its structural design. The optical converter is embedded in the transparent material with its emission direction perpendicular to the surface, and the waveguide is positioned such that its optical axis aligns with the converter's emission direction. This self-aligning structure eliminates the need for complex active alignment mechanisms during manufacturing.
Solution Approach 2:
The alignment is pre-established during the manufacturing of the optical sub-assembly. The optical converter and waveguide are positioned and fixed in their correct relative orientations before the assembly is used. This preliminary positioning ensures that no further active alignment is needed during installation or operation.
2Reliability
If conventional coupling devices are used, then optical signal coupling is achieved, but device size increases
Solution Approach 1:
The optical converter and waveguide are merged into a single integrated optical sub-assembly. The converter is embedded directly in the transparent material with the waveguide positioned in close proximity, eliminating the need for separate coupling components and reducing overall device size while maintaining effective optical coupling.
Solution Approach 2:
The optical converter is nested within the transparent material of the optical sub-assembly, with the waveguide positioned adjacent to it. This nested arrangement allows compact integration of multiple optical components in a small volume, achieving efficient coupling without requiring large device dimensions.
3Reliability
If conventional coupling devices are used, then optical signal transmission is achieved, but manufacturing cost and effort increase
Solution Approach 1:
The system is segmented into a modular optical sub-assembly that can be manufactured independently and then integrated into the larger system. This segmentation allows for specialized manufacturing processes optimized for the sub-assembly, reducing overall manufacturing complexity and cost while ensuring reliable optical transmission performance.
Solution Approach 2:
The optical sub-assembly is designed to be self-aligning and self-positioning, eliminating the need for complex active alignment procedures during manufacturing and installation. This self-service characteristic significantly reduces manufacturing effort and time while ensuring reliable optical coupling and transmission.
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
Enables low-loss, cost-effective optical signal coupling/decoupling with reduced latency, suitable for miniaturized applications, and high automation in production, achieving precise alignment and fast process speeds with low-cost placement machines.
Implementation Method 1
an optical sub-assembly (so-called optical sub-assembly or OSA) made in particular from at least one optically transparent or optically partially transparent medium
Data Source
Figure 1~2A
Figure 2B~3
Figure 4
AI summary
A device for coupling optical signals into at least one waveguide having at least one electro-optical converter, which sends out the optical signals in the direction of the axis or of the core of the waveguide, in such a way that active alignment of the waveguide is not necessary. The electro-optical converter is incorporated, in particular embedded, in at least one send-site optical subassembly, the send-site optical subassembly has at least one guiding channel for aligning the waveguide with respect to the electro-optical converter, in particular relative to the output port or to the active surface of the electro-optical converter, and at least one extension is assigned to the send-site optical subassembly, in particular to the guiding channel, the extension being provided for aligning the waveguide with respect to the guiding channel. Also, a device for decoupling optical signals from at least one waveguide having the features noted above.