Direct TOSA to Multiplexer Alignment for Optical Transceivers
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Solution Overview
Problem
Optical transceivers face challenges in scaling down while maintaining performance due to issues like insertion loss and polarization dependent loss (PDL) caused by optical components, which affect power efficiency and thermal management, particularly in achieving higher speeds and lower costs in smaller modules.
Innovation Solution
Direct alignment of transmitter optical subassembly (TOSA) modules with optical multiplexer inputs without using optical fibers, utilizing Z-rings for alignment and laser welding, eliminates the need for fiber arrays, reducing size and improving power consistency and overall performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If optical fibers are used to couple TOSA modules to optical multiplexer, then optical signals can be transmitted, but insertion loss and polarization dependent loss occur reducing power efficiency
Solution Approach 1:
The patent removes optical fibers from the coupling path between TOSA modules and optical multiplexer inputs. By directly aligning and coupling the TOSA modules to the multiplexer inputs without fiber intermediaries, the source of insertion loss and polarization dependent loss is eliminated, achieving direct optical coupling that maintains signal integrity and power efficiency
Solution Approach 2:
The patent introduces precision alignment structures (V-grooves, alignment marks, and positioning features) as intermediaries to enable direct coupling between TOSA modules and multiplexer inputs. These alignment mechanisms serve as mediators that facilitate precise optical coupling without requiring fiber arrays, thereby eliminating losses while maintaining coupling effectiveness
2Loss of energy
If optical fibers are used to couple TOSA modules to optical multiplexer, then optical signals can be transmitted, but polarization dependent loss reduces power consistency
Solution Approach 1:
The patent eliminates optical fibers from the coupling path, thereby removing the source of polarization dependent loss. By implementing direct optical coupling between TOSA modules and multiplexer inputs through alignment structures, the system avoids fiber-related polarization effects and achieves consistent power delivery across all channels
3Volume of moving object
If fiber arrays are used for coupling, then TOSA modules can be connected to optical multiplexer, but additional space is required in transmitter housing
Solution Approach 1:
The patent removes fiber arrays from the transmitter housing, eliminating the space they occupy. By implementing direct coupling with alignment structures integrated into the housing or module mounts, the system achieves a more compact configuration that reduces overall transmitter size while maintaining functional connectivity
Solution Approach 2:
The patent integrates alignment structures and coupling mechanisms directly into the transmitter housing or module assembly, merging previously separate components (fibers, connectors, alignment features) into a unified integrated structure. This consolidation eliminates the need for separate fiber array management and reduces the overall space required
4Productivity
If channel density and speed are increased, then transmission performance improves, but maintaining nominal transceiver performance becomes more difficult
Solution Approach 1:
The patent replaces the mechanical fiber coupling system with a direct optical coupling approach using precision alignment structures. This substitution eliminates the variability introduced by fiber placement and manual alignment, providing more consistent and reliable optical coupling that maintains performance consistency even as channel density and speeds increase
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 enhances power consistency and performance by eliminating insertion loss and PDL associated with fiber arrays, allowing for smaller, more efficient optical transceivers capable of higher speeds and longer distances, such as 25 Gbps per channel over 2 kilometers.
Implementation Method 1
Each of the plurality of transmitter optical subassembly (TOSA) modules for transmitting a plurality of optical signals at different respective channel wavelengths
Implementation Method 2
Z-rings may be used to facilitate alignment and to mount the TOSA bases to the side wall of the multiplexer housing, for example, by laser welding
Data Source
AI summary
A multi-channel optical transmitter or transceiver includes transmitter optical subassembly (TOSA) modules optically coupled to and directly aligned with mux input ports of an optical multiplexer without using optical fibers. The optical multiplexer may include an arrayed waveguide grating (AWG) or a reversed planar lightwave circuit (PLC) splitter and may be located in a multiplexer housing having at least one side wall with input apertures aligned with the mux input ports. The TOSA modules may include a base supporting at least a laser, laser driving circuitry, and a lens for focusing the light output from the laser. Z-rings may be used to facilitate alignment and to mount the TOSA bases to the side wall of the multiplexer housing, for example, by laser welding.