Transmitter Optical Subassembly Lens Alignment Method
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Solution Overview
Problem
Existing transmitter optical sub-assemblies (TOSAs) with wavelength division multiplexing (WDM) functions do not adequately meet the demands for increased transmission capacity with reduced power consumption and improved coupling efficiency between optical fibers and signal sources, particularly in smaller form factor optical transceivers like CFP.
Innovation Solution
A method for assembling a transmitter optical module that involves preparing an intermediate assembly with a semiconductor laser diode, substrate, and housing, using a supplementary jig to align and position lenses for optimal beam collimation and coupling, and fixing them using adhesive resin cured by UV or heat, ensuring precise alignment and efficient beam multiplexing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional TOSA designs are used, then basic WDM function is achieved, but coupling efficiency between optical fiber and signal source is insufficient
Solution Approach 1:
The patent introduces a lens as an intermediary component between the laser diode and optical fiber. This lens mediates the optical beam transformation, converting the divergent beam from the laser diode into a collimated or focused beam that can be efficiently coupled into the optical fiber, thereby resolving the coupling efficiency problem without requiring direct precise alignment between the laser diode and fiber
Solution Approach 2:
The patent performs preliminary alignment and positioning of the lens relative to the laser diode during the assembly process. By pre-positioning the lens at the correct location and orientation before final assembly, the system establishes optimal optical coupling conditions in advance, eliminating the need for complex real-time alignment adjustments
2Quantity of substance
If transmission capacity is increased, then information volume is enhanced, but power consumption increases
Solution Approach 1:
The patent optimizes optical coupling parameters such as beam collimation, focus position, and numerical aperture matching between the optical system and fiber. By carefully adjusting these optical parameters, the system achieves maximum power transfer efficiency, ensuring that increased transmission capacity is achieved with minimal power loss and optimized energy utilization
3Volume of moving object
If form factor is reduced, then device size is minimized, but alignment precision becomes more difficult to maintain
Solution Approach 1:
The patent employs a compact nested structure where the lens is positioned within a housing that integrates multiple components. The lens is nested within the housing structure, and the optical path is carefully designed to maintain precise alignment relationships despite the reduced overall device size, allowing compact form factor while preserving alignment precision
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 coupling efficiency and transmission capacity while reducing power consumption by ensuring precise alignment and fixation of lenses, resulting in improved performance and efficiency in smaller form factor optical transceivers.
Implementation Method 1
The supplementary jig may include two prisms each reflecting the optical beam output from the LD to offset the optical axis of the optical beam
Implementation Method 2
aligning a first lens, as monitoring the optical beam, in a position where the optical axis of the first lens coincides with that of the LD and the optical beam passing through the first lens becomes a collimated beam
Implementation Method 3
curing the adhesive resin by irradiating the resin with ultraviolet rays and/or heating the resin
Implementation Method 4
curing the adhesive resin by irradiating the resin with ultraviolet rays and/or heating the resin
Data Source
AI summary
A method to assemble a transmitter optical module is disclosed, where the optical module installs two lenses, one of which concentrates an optical beam emitted from a laser diode, while, the other collimates the optical beam concentrated by the former lens. The method has a feature that the first lens is firstly positioned in a point to collimate the optical beam coming from the laser diode, then, moved to a point, which is apart from the former point with respect to the laser diode, to concentrate the optical beam. The process performs the steps to position the lens by a jig to extract the optical beam passing through the first lens outside of the housing.