Optical Waveguide With Integrated Mount Opening

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Solution Overview

Problem

Existing optical modules face challenges in cost reduction and mass production due to the need for separate substrates and multiple steps in forming projections or recesses for mounting optical elements, which increases complexity and material costs.

Innovation Solution

An optical waveguide with a reflective surface and an element mount opening in the clad allows for optical element mounting without a separate height adjustment member, integrating the mount opening within the waveguide material to align with the reflective surface, thereby simplifying the mounting process and reducing material costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a separate substrate with projections or recesses is used to mount optical elements, then optical elements can be mounted, but the number of components and manufacturing steps increases

Engineering Contradiction:

Improvemounting process simplicityVSAvoidnumber of components

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges the optical waveguide and the mounting substrate into a single integrated structure. The optical waveguide is formed directly on the substrate with its core extending to form a reflective surface, eliminating the need for separate mounting projections or recesses. This integration reduces the number of components and simplifies the manufacturing process while maintaining the ability to mount optical elements effectively.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If multiple steps are used to form projections or recesses in the substrate, then mounting structures are created, but cost reduction and mass production become difficult

Engineering Contradiction:

Improvemounting structure formationVSAvoidmass production efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent segments the mounting function from the substrate formation process. Instead of forming complex projections or recesses in the substrate, the design uses the natural extension of the optical waveguide core to create the mounting interface. This segmentation allows the substrate to remain simple and flat, suitable for mass production, while the waveguide structure provides the necessary mounting features.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The optical waveguide core serves multiple functions: it guides light transmission and simultaneously forms the reflective surface that acts as the mounting interface for optical elements. This multi-functionality eliminates the need for separate mounting structures, simplifying the manufacturing process and enabling cost-effective mass production.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If additional platforms and height adjustment members are used, then optical alignment is achieved, but material costs increase

Engineering Contradiction:

Improveoptical alignmentVSAvoidmaterial costs

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The optical waveguide structure is designed to be self-aligning. The reflective surface formed by the waveguide core extension naturally provides the mounting interface at the correct height and position, eliminating the need for separate height adjustment members or additional alignment platforms. This self-service approach reduces material costs while maintaining manufacturing precision.

Inventive Principle:

Principle #25Self-service

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 solution enables cost-effective mass production of optical modules by eliminating the need for additional platforms and height adjustment steps, ensuring efficient optical coupling and reducing material costs.

Implementation Method 1

a reflective surface from which an end face of the waveguide core is exposed, the reflective surface being provided on an inclined face at one end face of the optical waveguide

Methodology Applied

Scientific EffectReflection: Reflection

Implementation Method 2

a clad configured to trap the light in the waveguide core

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Data Source

PatentUS8100589B2Optical module and optical waveguide

Publication Date: 2012.01.24 SONY GROUP CORP

AI summary

An optical module includes an optical waveguide including a waveguide core through which light propagates and a clad configured to trap the light in the waveguide core, and a circuit board on which a surface-type optical element is mounted. The optical waveguide further includes a reflective surface from which an end face of the waveguide core is exposed, the reflective surface being provided on an inclined face at one end face of the optical waveguide core in an extending direction of the waveguide core, and an element mount opening provided in the clad such as to be opposite from the reflective surface, the element mount opening having a size such as to contain the optical element. The optical waveguide is mounted on the circuit board while the optical element is contained in the element mount opening and is aligned with the reflective surface of the optical waveguide.