Tapered Recess Sub-Mount for Optical Component Mounting
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Solution Overview
Problem
Existing methods for mounting optical components in optical wiring devices require precise positioning and embedding of mirrors, leading to high costs due to the need for expensive equipment and complex manufacturing processes, which increases the overall cost of the devices.
Innovation Solution
A sub-mount with a tapered recess for mounting optical components, allowing for easy and reliable embedding and mounting of optical components, and a manufacturing method using anisotropic etching on a silicon monocrystal substrate to produce a mold for duplicating the sub-mount, enabling high-precision and cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precise positioning and embedding of mirrors is used to mount optical components, then mounting precision is improved, but manufacturing cost increases due to expensive equipment and complex processes
Solution Approach 1:
The invention extracts the mirror component from the mounting structure and replaces it with a tapered recess design. The optical component is directly mounted in the tapered recess without requiring a separate mirror, thereby eliminating the need for expensive mirror embedding equipment and complex positioning processes while maintaining mounting precision
Solution Approach 2:
Instead of using a mirror to redirect light and achieve precise positioning, the invention inverts the approach by using a tapered recess structure that directly guides and positions the optical component. The taper angle of the recess provides the positioning function that previously required a mirror, simplifying the manufacturing process and reducing costs
2Manufacturing precision
If high precision positioning is required when laminating waveguide and light transmission reception element, then assembly precision is improved, but device complexity increases
Solution Approach 1:
The tapered recess structure provides self-aligning and self-positioning capabilities during the lamination process. The taper angle guides the optical component into the correct position automatically, eliminating the need for complex external positioning devices and high-precision positioning mechanisms, thereby reducing device complexity while maintaining assembly precision
3Manufacturing precision
If expensive equipment such as RIE is used to manufacture sub-mount with precise shape, then manufacturing precision is improved, but productivity decreases due to high cost and complex processes
Solution Approach 1:
The invention changes the geometric parameters of the recess from a conventional shape to a tapered shape with specific angle ranges (30-60 degrees). This parameter change allows the recess to be manufactured using simpler, more cost-effective processes while maintaining the necessary precision for optical component mounting, thereby improving productivity and reducing manufacturing costs
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
The solution enables the mass production of optical components with high precision and low costs, facilitating the assembly of compact light transmission and reception modules with improved flexibility and reduced manufacturing expenses.
Implementation Method 1
a manufacturing method using anisotropic etching on a silicon monocrystal substrate to produce a mold for duplicating the sub-mount
Data Source
AI summary
A sub-mount for mounting optical components includes a recess for mounting whose side wall is tapered. A light transmission and reception module includes the sub-mount for mounting optical component. The sub-mount is manufactured by forming a master mold of the sub-mount formed with projections and recesses including the recess for mounting of the sub-mount, applying liquid silicone rubber to the mater mold, curing the liquid silicone rubber to produce a mold for duplication, filling the curable material into the mold for duplication, curing the curable material, and separating the cured curable material from the mold for duplication.