Optoelectronic Device Support Member Alignment
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Solution Overview
Problem
The high precision required for optical connectors in optoelectronic systems makes them expensive and difficult to manufacture, as traditional manufacturing processes like plastic injection molding and metal forming struggle to achieve micron-level tolerances, leading to increased production costs and complexity.
Innovation Solution
The optoelectronic device is designed with a high precision optical socket and a lower precision support member, allowing the optical socket to be reused across various system geometries, with the support member providing additional attachment strength and reducing manufacturing costs by using existing qualified parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing processes like plastic injection molding and metal forming are used to manufacture optical connectors, then production costs and manufacturing complexity increase, but manufacturing precision cannot achieve micron-level tolerances
Solution Approach 1:
The optical connector assembly is divided into two functional segments: a support member that provides mechanical strength and positioning, and an optical socket that provides precise alignment features. This segmentation allows each component to be manufactured using appropriate processes - the support member can be made with conventional molding or forming, while the optical socket can be precision-machined or additively manufactured to achieve micron-level tolerances for optical alignment.
Solution Approach 2:
The support member acts as an intermediary component between the substrate and the optical socket. It provides a mounting interface that is easier to manufacture while supporting the high-precision optical socket. The support member includes features like recesses and protrusions that facilitate assembly without requiring the entire assembly to be manufactured with micron-level precision.
2Manufacturing precision
If optical sockets are precisely molded or manufactured to provide proper alignment, then alignment precision is improved, but production costs increase
Solution Approach 1:
By separating the optical socket from the support member, only the socket portion requires expensive precision manufacturing processes. The support member can be produced using cost-effective conventional processes. This segmentation reduces overall production costs while maintaining the alignment precision needed for optical connectivity.
Solution Approach 2:
The optical socket is designed as a universal component that can be used across different system geometries and configurations. By standardizing the socket design and interface features, the expensive precision-manufactured component can be reused in multiple applications, amortizing the high manufacturing cost across larger production volumes.
3Manufacturing precision
If optical sockets are precisely molded or manufactured to provide proper alignment, then alignment precision is improved, but device complexity increases
Solution Approach 1:
Dividing the assembly into a simple support member and a precision optical socket reduces overall structural complexity. The support member handles mechanical functions with simple geometry, while the optical socket contains the alignment features in a dedicated component. This separation makes each individual component simpler to design and manufacture.
Solution Approach 2:
The complex alignment features are extracted from the overall assembly and concentrated in the optical socket component. This allows the support member and substrate to maintain simple structures, while the extracted socket component can be optimized specifically for alignment functions without adding complexity to the entire device.
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
Optoelectronic devices with a support member and methods of manufacturing or assembling the same are provided. An example of an optoelectronic device according to the present disclosure includes a substrate and an optical component and an electronic component disposed thereon or therein. The optoelectronic device further includes a ferrule coupled to the optical fiber and an optical socket receiving the ferrule therein. The optoelectronic device includes a support member disposed between the substrate and the optical socket such that the optical socket is spaced from the substrate by the support member.