Passive Alignment Optical Device Using Reference Parts
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Solution Overview
Problem
Conventional optical alignment methods for fiber optics are costly and time-consuming due to the need for active alignment techniques, which require expensive equipment and complex processes, especially in high-capacity digital media transmissions.
Innovation Solution
An optical device and method utilizing a substrate with an alignment reference part to passively align light-emitting and light-receiving elements with a lens-optical fiber connection, reducing the number of parts and eliminating the need for active alignment by using a focusing lens and prism to secure and align optical fibers without additional structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If active optical alignment is used to align optical elements with optical fibers, then alignment precision is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent introduces alignment reference parts (alignment marks, reference patterns) as intermediary elements that mediate between optical elements and optical fibers. These reference parts provide fixed geometric references that enable passive alignment without requiring active optical measurement systems, thus reducing complexity while maintaining precision
Solution Approach 2:
The alignment reference parts are pre-formed on the substrate before optical element mounting. This preliminary action establishes fixed alignment references in advance, eliminating the need for real-time active alignment during assembly and simplifying the manufacturing process
2Manufacturing precision
If active optical alignment with real-time detection is used, then alignment precision is improved, but manufacturing time increases
Solution Approach 1:
The alignment reference parts enable the system to self-align through predetermined geometric relationships. Optical elements and fibers align themselves using the reference parts as guides, eliminating the need for time-consuming active measurement and adjustment processes
Solution Approach 2:
The patent extracts the alignment function from the optical path itself and places it in separate alignment reference parts. This separation allows alignment to occur through simple mechanical positioning rather than requiring complex real-time optical detection and adjustment
3Manufacturing precision
If conventional optical alignment equipment is used, then alignment precision is improved, but manufacturing cost increases
Solution Approach 1:
The alignment reference parts are simple, inexpensive geometric features (marks, patterns) that can be easily formed on substrates using low-cost processes. These replace expensive alignment equipment while providing sufficient precision for mass production
Solution Approach 2:
The alignment reference parts serve as inexpensive intermediary elements that mediate alignment between optical components. Instead of investing in costly active alignment equipment, the system uses simple geometric references that provide adequate precision at minimal cost
4Manufacturing precision
If multiple alignment structures are used to align optical elements and fibers, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The alignment reference parts serve multiple functions: they provide alignment references for both optical element mounting and optical fiber positioning. This multi-functionality eliminates the need for separate alignment structures for different components, reducing overall device complexity
Solution Approach 2:
The patent merges the alignment reference function into the substrate itself rather than using separate alignment structures. The reference parts are integrated into the substrate, combining the substrate and alignment reference into a single element, thereby reducing the total number of components
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 and speeds up the alignment process, minimizes alignment errors, and reduces costs, enabling efficient mass production of optical modules for high-speed data communication with reduced reflection loss and structural complexity.
Implementation Method 1
a lens-optical fiber connection means 120 for collecting light, altering an optical path, and securing and aligning the optical fiber 133
Implementation Method 2
a lens-optical fiber connection means 120 for collecting light, altering an optical path, and securing and aligning the optical fiber 133
Data Source
AI summary
An optical device for implementing passive alignment of parts and a method therefor, more particularly an optical device and a method therefor that utilize an alignment reference part arranged on the substrate to passively align an optical element part with a lens-optical fiber connection part.For the passive alignment of parts, connection pillars of an alignment reference part are coupled to substrate holes, one or more light-emitting elements and one or more light-receiving elements are aligned in a row in a particular interval with respect to alignment holes arranged opposite each other in the alignment reference part, a lens-optical fiber connection part is aligned with respect to the alignment holes, and an optical fiber is aligned with the optical alignment point at a surface of a prism forming a portion of the lens-optical fiber connection part.