Unibody Optical Transceiver Module Single-Piece Substrate Alignment
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Solution Overview
Problem
Existing optical transceiver modules face challenges with robust alignment and reliability due to separate construction of optical interfaces and engines, which can be affected by package deterioration, and require smaller form factors and lower manufacturing costs.
Innovation Solution
Integration of optical interfaces and engines using a single-piece substrate, allowing for aligned component assembly within the package, reducing the impact of package deterioration and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If optical interface and optical engine are constructed as separate units and attached to package, then manufacturing flexibility is improved, but alignment robustness and reliability deteriorate due to package deterioration affecting coupling alignment
Solution Approach 1:
The patent merges the optical interface and optical engine into a single integrated unit where the optical engine is directly coupled to the optical interface components. This integration eliminates the separate attachment steps and removes the package as an intermediate mounting structure, thereby maintaining manufacturing flexibility while significantly improving alignment robustness and reliability by eliminating the alignment interface that is susceptible to package deterioration.
2Adaptability or versatility
If optical interface and optical engine are constructed as separate units, then component independence is improved, but device size increases due to additional packaging and mounting structures
Solution Approach 1:
The patent combines the optical interface and optical engine into a compact integrated structure, eliminating the need for separate packaging and mounting structures. This integration maintains the functional independence of components while reducing the overall device volume by removing redundant structural elements and minimizing the space required for assembly.
3Ease of manufacture
If separate construction method is used for optical interface and optical engine, then manufacturing process flexibility is improved, but manufacturing cost increases due to multiple assembly steps and alignment requirements
Solution Approach 1:
The patent integrates the optical interface and optical engine into a unified structure that can be manufactured as a single unit or pre-assembled module. This approach maintains process flexibility for design variations while reducing manufacturing costs by eliminating multiple assembly steps, reducing alignment requirements, and decreasing the number of components that need to be handled and assembled separately.
Data Source
AI summary
An optical transceiver module having unibody structure is disclosed. The unibody structure comprises a single-piece substrate, an optical interface, and an optical engine. The components of the optical interface and the components of the optical engine are directly attached to the single-piece substrate.