Common Optical Substrate Layout for Compact Multi-Laser Engines
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Solution Overview
Problem
Existing optical communication systems face challenges in reducing size while increasing data transmission capacity, requiring multiple laser sources within a compact module while maintaining low cost and complexity.
Innovation Solution
A common optical reference substrate is used to efficiently align and couple a fiber array with an array of discrete laser diode devices, incorporating alignment fiducials and bond locations, and positioning passive optical devices directly on the substrate to simplify fabrication and reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple laser sources are incorporated within a given sub-system to increase data transmission capacity, then the transmission capacity is improved, but the size and complexity of the module increases
Solution Approach 1:
The patent combines multiple laser diode devices and fiber array on a single common substrate, integrating what would traditionally be separate components into one unified structure. This merging approach increases data transmission capacity through multiple sources while avoiding the complexity increase that would result from multiple separate modules or mounting procedures
Solution Approach 2:
The common substrate serves multiple functions simultaneously: it provides mechanical support for both the laser diode array and fiber array, establishes precise optical alignment between them, and enables thermal management. This multi-functionality reduces the need for additional specialized components, thereby increasing transmission capacity without proportionally increasing module complexity
2Productivity
If multiple laser sources are incorporated within a given sub-system to increase data transmission capacity, then the transmission capacity is improved, but the footprint of the module increases
Solution Approach 1:
The patent transitions from a traditional linear or planar arrangement of laser sources to a two-dimensional array configuration mounted on a common substrate. This dimensional change allows multiple laser sources to be packed more efficiently in a compact footprint while maintaining the necessary spacing for optical coupling, thus increasing transmission capacity without proportionally increasing the module area
3Ease of operation
If alignment fiducials are used on a common optical reference substrate to simplify alignment, then the alignment efficiency is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The alignment fiducials are pre-formed on the common substrate during the substrate fabrication process itself, before the laser diode array and fiber array are mounted. This preliminary action establishes the alignment reference framework in advance, simplifying subsequent assembly operations while the precision requirements are managed through standardized fabrication processes
Data Source
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AI summary
A laser source assembly is based upon an optical reference substrate that is utilized as a common optical reference plane upon which both a fiber array and a laser diode array are disposed and positioned to provide alignment between the components. Passive optical components used to provide alignment between the laser diode array and the fiber array are also located on the optical reference substrate. A top surface of the reference substrate is patterned to include alignment fiducials and bond locations for the fiber array receiving block, laser diode array submount and passive optical components. The receiving block is configured to present the optical fibers at a height that facilitates alignment with the output beams from the laser diodes positioned on the silicon submount.