Self-Correcting Optical Alignment for Hybrid Integrated Elements
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for integrating and aligning optical components in hybrid optical assemblies face challenges with accurate optical coupling and alignment, particularly due to manufacturing errors and geometric inaccuracies, which can lead to positional offsets and increased complexity in the integration process.
Innovation Solution
The solution involves a method of forming an assembly of optically linked optical components using a motherboard with primary lateral reference surfaces and a daughterboard with secondary and tertiary lateral reference features, allowing for self-correcting alignment and passive optical linking, which minimizes the risk of damage to delicate components during alignment and facilitates easier testing and integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If mechanical alignment methods are used to integrate optical components, then the components can be separately manufactured and optimized, but manufacturing errors and geometric inaccuracies lead to positional offsets and misalignment
Solution Approach 1:
The patent introduces an intermediary alignment mechanism consisting of alignment features (such as alignment holes, pins, or mechanical stops) that mediate between separately manufactured components. These alignment features act as reference elements that compensate for manufacturing tolerances and geometric inaccuracies, enabling precise positioning of optical components without requiring ultra-precise manufacturing of all surfaces.
Solution Approach 2:
The alignment system is designed to be self-aligning through complementary mechanical features that automatically guide components into correct positions during assembly. The alignment features on mating components work together to establish precise relative positioning without requiring external alignment tools or complex adjustment procedures, thereby maintaining both separate manufacturability and high alignment accuracy.
2Manufacturing precision
If complex alignment procedures are implemented to achieve accurate optical coupling, then alignment precision improves, but the integration process becomes more complex and time-consuming
Solution Approach 1:
The patent implements preliminary alignment actions by pre-forming alignment features on components during their respective manufacturing processes. These alignment features (such as precision-machined holes, protrusions, or reference surfaces) are created in advance and designed to work together during final assembly, thereby simplifying the integration process while ensuring accurate optical coupling without requiring complex real-time alignment procedures.
3Manufacturing precision
If delicate optical components are directly handled during alignment, then precise positioning can be achieved, but the risk of mechanical damage to the components increases
Solution Approach 1:
The patent uses intermediary mechanical alignment features (such as alignment pins fitting into alignment holes, or mechanical stops) that serve as mediators between the handling mechanism and the delicate optical components. These intermediary features bear the mechanical loads and positioning stresses during assembly, thereby protecting the fragile optical components from direct mechanical contact and potential damage while still achieving precise positioning.
4Manufacturing precision
If multiple separate alignment features are used to locate optical components, then positioning accuracy improves, but the number of manufacturing steps and process complexity increases
Solution Approach 1:
The patent combines multiple alignment functions into integrated alignment features. For example, a single alignment feature may simultaneously provide lateral positioning, axial positioning, and rotational orientation. This merging of alignment functions reduces the total number of separate alignment features required, thereby simplifying the manufacturing process and improving productivity while maintaining high positioning accuracy through the multi-functional design of each alignment feature.
Data Source
Figure 1a~1c
Figure 2a~2c
Figure 3a~3c
AI summary
The present invention provides an assembly (1) of integrated optical components and methods of producing thereof wherein the assembly (1) of optically linked optical components comprises a motherboard (2) having one or more primary lateral reference features (28) and a sub-assembly (20) comprising an optical component (22) mounted on a daughterboard (24), said sub-assembly (20) having one or more secondary lateral reference features (30). The primary lateral reference features may be optical alignment features. The daughterboard (24) may be mounted on the motherboard (2) such that the optical component (22) may extend into a motherboard recess (18). The lateral alignment of the component (22) with the motherboard (2) is provided by aligning the primary (28) and secondary lateral reference features (30). The daughterboard (24) may further comprise tertiary lateral reference features (42) which in combination with the secondary lateral reference features 30 form a self correcting alignment system.