Optical Sub-Assembly Passive Alignment Housing Structure
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Solution Overview
Problem
Current optical transceiver modules face high costs and inefficiencies due to active alignment processes, which are time-consuming and prone to errors, while passive alignment methods lack precision and are costly, leading to suboptimal coupling efficiency and production yield.
Innovation Solution
An optical sub-assembly with a base featuring an alignment part and a housing that uses an aspherical lens for optical coupling, where the housing's interior surface and base's side surface have distinct curvatures to stabilize the fiber and photoelectric component alignment, allowing for secure and efficient passive alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If active alignment process is used for optical coupling, then coupling efficiency is improved, but production time and cost increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-positioning the optical component and fiber in a fixed spatial relationship during the packaging process. The housing structure with precisely positioned windows and mounting features ensures that alignment is established before final assembly, eliminating the need for time-consuming active alignment adjustments during production.
Solution Approach 2:
The patent replaces the mechanical active alignment system with a precision-molded housing structure that provides passive alignment through its geometric features. The interlocking base and housing components with precisely formed windows and mounting surfaces substitute for mechanical adjustment mechanisms, achieving high coupling efficiency through precision molding rather than mechanical alignment.
2Ease of manufacture
If passive alignment process with etching technique is used, then cost is reduced, but position precision deteriorates
Solution Approach 1:
The patent extracts the expensive etching step from the manufacturing process by using precision injection molding to directly form the alignment features in the housing and base. The V-shaped slots, windows, and mounting surfaces are created during molding rather than requiring subsequent etching operations, eliminating the costly etching technique while maintaining position precision.
Solution Approach 2:
The patent changes the manufacturing parameter from post-molding etching to precision molding itself. By utilizing the capabilities of high-precision injection molding to directly create the alignment features with the required dimensional accuracy, the process achieves both cost reduction and position precision without requiring expensive etching operations.
3Manufacturing precision
If active alignment process is used, then coupling efficiency is improved, but design tolerance and stability against heat, shake or shock are reduced
Solution Approach 1:
The patent merges the alignment function with the structural housing design. The base and housing are designed as interlocking components with integrated alignment features, where the V-shaped slots, windows, and mounting surfaces work together as a unified structure. This integration ensures that the alignment relationship is mechanically locked and stable against environmental disturbances.
Solution Approach 2:
The patent utilizes curved V-shaped surfaces in the base and corresponding features in the housing to provide self-aligning and stability characteristics. The curved surfaces allow for tolerance compensation while maintaining optical alignment, and the geometric shape provides mechanical stability against heat expansion, vibration, and shock by distributing stresses evenly.
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 reduces fabrication costs, minimizes packaging time, and enhances coupling efficiency, achieving results comparable to active alignment while avoiding its drawbacks.
Implementation Method 1
uses an aspherical lens for optical coupling
Data Source
AI summary
The present invention discloses an optical sub-assembly (OSA) comprising: a base; at least one photoelectric component; and a housing. The base includes an alignment part including an upper surface and a side surface; the side surface includes a first surface and a second surface; and the first and second surfaces have different curvatures and/or constitute a discontinuous surface. Said photoelectric component is set upon the upper surface for optically connecting to a fiber. Said housing includes a window and an interior surface in which the window is for inserting the fiber, and the interior surface is for defining an accommodation room and includes a third surface and a fourth surface. The accommodation room is capable of containing at least some of the alignment part; meanwhile, the third surface closely meets the first surface and the fourth surface closely meets the second surface.