Tilted-Plane Optical Paths for High-Density Modules

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Solution Overview

Problem

Existing optical modules with stepping configurations for COS components and folding mirrors face limitations in density due to beam blocking and thermal path differences, leading to reduced output power, reliability, and spectral linewidth.

Innovation Solution

The optical module employs tilted-plane optical paths by angling mirrors relative to the substrate's surface, eliminating stepping and allowing for a higher density of COS components and mirrors, while maintaining consistent thermal paths.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If stepping configurations are used for COS components and folding mirrors, then beam blocking is avoided, but device density is reduced

Engineering Contradiction:

Improvedensity of COS components and mirrorsVSAvoidbeam blocking

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The patent transitions from horizontal beam paths to tilted-plane optical paths by angling mirrors relative to the substrate surface. This dimensional change in beam propagation allows higher density packaging of COS components and mirrors without beam blocking, as beams travel through three-dimensional space rather than confined horizontal planes.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If stepping configurations are used for COS components and folding mirrors, then beam paths are separated, but thermal path differences increase

Engineering Contradiction:

Improvethermal management consistencyVSAvoidthermal differentials

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent merges the optical path tilting function into a single substrate structure that simultaneously guides all beams through tilted planes. This unified approach ensures all COS components operate at the same temperature, eliminating thermal differentials while maintaining beam separation through the tilted-plane configuration.

Inventive Principle:

Principle #5Merging (Combining)

3Quantity of substance

If tilted-plane optical paths are implemented, then device density increases, but manufacturing complexity increases

Engineering Contradiction:

Improvedensity of COS components and mirrorsVSAvoidmirror angling precision

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The substrate is designed with self-aligning features that automatically position mirrors at the correct tilted angles during assembly. This self-service mechanism reduces the need for complex precision alignment procedures, making the tilted-plane configuration manufacturable despite the increased density requirements.

Inventive Principle:

Principle #25Self-service

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 configuration increases the density of COS components and mirrors, reduces thermal differentials, and improves power, reliability, and spectral linewidth by avoiding beam blocking and ensuring consistent thermal management.

Implementation Method 1

each mirror, of the plurality of mirrors, is angled, non-orthogonally, with respect to the single, horizontal plane, such that each optical path associated with each mirror is disposed in a corresponding tilted plane

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS20250044602A1Optical module with tilted-plane optical paths

Publication Date: 2025.02.06 WELLS FARGO BANK NA

AI summary

In some implementations, an optical component includes a substrate component; and a plurality of mirrors disposed on a top surface of the substrate component in a single, horizontal plane, wherein each mirror, of the plurality of mirrors, is angled, non-orthogonally, with respect to the single, horizontal plane, such that each optical path associated with each mirror is disposed in a corresponding tilted plane that is non-parallel with the single, horizontal plane.