Varying Gap Projections for Self-Aligned Optical Waveguide Coupling
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Solution Overview
Problem
In optical devices employing self-alignment for hybrid mounting, the accuracy of optical coupling between optical waveguides is compromised due to manufacturing inaccuracies in projections, leading to increased coupling loss and displacement of optical waveguide components.
Innovation Solution
The optical device incorporates a substrate with varying gap projections and an optical waveguide component with aligning projections that contact each other, ensuring precise alignment and minimizing positional displacement, thereby enhancing the accuracy of optical coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If side faces of projections are simply brought into contact with each other for alignment, then the alignment process is simple, but manufacturing inaccuracies cause displacement and reduce optical coupling accuracy
Solution Approach 1:
The patent applies local quality by creating a gap between the side faces of the projections that varies in width along the optical axis direction. This non-uniform gap structure provides different alignment characteristics at different positions, enabling the movable component to be automatically positioned at the correct location where the gap is appropriately sized, thereby achieving both simple alignment operation and high optical coupling accuracy
Solution Approach 2:
The patent changes the geometric parameter of the projection gap by making the gap width vary along the optical axis direction. This parameter variation creates a unique positioning condition where the movable component naturally settles at the correct position during the alignment process, resolving the contradiction between simple alignment and precise optical coupling
2Ease of operation
If projections are made with larger size to improve alignment, then alignment is easier, but individual differences in projection size increase due to manufacturing inaccuracies
Solution Approach 1:
Instead of uniformly enlarging projections, the patent introduces a varying gap structure between projection side faces. This local variation in gap width provides a self-positioning mechanism that compensates for individual differences in projection dimensions, ensuring consistent alignment results across different components manufactured with standard tolerances
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 improves the accuracy of optical coupling by aligning the optical waveguide components with high precision, reducing relative positional displacement and coupling loss, even with manufacturing inaccuracies in the projections.
Implementation Method 1
a force based on surface tension of the solder between the opposed electrode patterns is applied from the solder to the electrode pattern of the second optical waveguide component
Data Source
AI summary
An optical device includes a substrate. The substrate includes a first optical waveguide component having a first optical waveguide, a pair of first projections in which a gap between side faces thereof varies in a direction along an optical axis of the first optical waveguide, and a first pattern. The optical device includes a second optical waveguide component. The second optical waveguide component includes a second optical waveguide, at least one pair of second projections, and a second pattern. The second pattern and the first pattern are soldered to each other and side faces of the at least one pair of second projections are in contact with the side faces of the pair of first projections, respectively.