Optoelectronic Package Alignment Using a Movable Lens
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Solution Overview
Problem
The existing methods for manufacturing optoelectronic structures require complex and time-consuming active alignment processes, especially when dealing with large and complex light source modules, which necessitate a special setup and design for moving the modules while powered up, complicating the alignment process.
Innovation Solution
The method involves passively aligning optical components and using a lens structure to actively align the light source modules with photonic components by moving the lens to a unit-specific position, simplifying the setup and reducing alignment time and cost, as the light source modules are not powered up during initial placement, and a common vacuum head can be used for moving the lens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the light source module is actively aligned by moving the entire module while powered up, then the optical signal coupling is optimized, but the device complexity and setup requirements increase significantly
Solution Approach 1:
The patent introduces a lens structure as an intermediary component between the light source module and the photonic component. Instead of moving the entire light source module, only the lightweight lens is moved to achieve active alignment. This mediator approach simplifies the alignment setup while maintaining optimal optical coupling.
Solution Approach 2:
The alignment function is segmented from the light source module itself and assigned to a separate lens structure. This segmentation allows the lens to be moved independently using simple vacuum head tools, whereas moving the entire powered-up light source module would require complex specialized equipment.
2Measurement precision
If the light source module is moved during active alignment while powered up, then the optimum optical signal is achieved, but the alignment process becomes time-consuming and complex
Solution Approach 1:
By using a lens as an intermediary that can be quickly moved and repositioned, the alignment process is accelerated. The lens can be rapidly adjusted to different positions without the time-consuming process of moving and repositioning an entire light source module while maintaining power and monitoring optical signals.
Solution Approach 2:
The complex mechanical system of moving a powered-up light source module is replaced with a simpler mechanical system of moving a lightweight lens using vacuum head tools. This substitution dramatically reduces the time and complexity of the active alignment process.
3Ease of operation
If a specialized pick-up head is designed to move the light source module, then the active alignment can be performed, but the device complexity and manufacturing cost increase
Solution Approach 1:
The lens serves as a mediator that can be manipulated by simple, standardized vacuum head tools rather than requiring specialized pick-up heads. This intermediary approach maintains active alignment capability while eliminating the need for complex specialized handling equipment.
Solution Approach 2:
Instead of designing a specialized pick-up head for the unique light source module, the patent uses a common, standardized vacuum head tool to manipulate the lens. This copying of a standard tool approach reduces manufacturing complexity and cost while achieving the same alignment function.
4Measurement precision
If the light source module is used as the moving element in active alignment, then the optical components are aligned, but the weight and volume of the moving object increase
Solution Approach 1:
The lens acts as a lightweight intermediary that replaces the heavy light source module as the moving element. This mediator has minimal weight and volume compared to the entire light source module, making it much easier to manipulate during active alignment while still achieving precise component alignment.
Solution Approach 2:
The alignment function is extracted from the heavy light source module and assigned to a separate, lightweight lens structure. This extraction allows the alignment process to use a minimal-mass moving object, significantly reducing the weight and volume of the moving element while maintaining alignment precision.
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 simplifies the alignment process, reduces the time and cost of aligning optical components, and allows for a more flexible and efficient setup by using a simpler lens structure with less weight and volume, eliminating the need for a specialized pick-up head.
Implementation Method 1
adjusting a lens structure to a unit specific position related to the substrate to couple an optical signal from the light source module to the photonic component
Data Source
AI summary
A method for manufacturing an optoelectronic structure and a package structure are provided. The method includes providing a substrate and a light source module and a photonic component over the substrate; and adjusting a lens structure to a unit specific position related to the substrate to couple an optical signal from the light source module to the photonic component.