Vertical Mount Optical Assembly for Multi-Angle Light Path Alignment
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Solution Overview
Problem
The design and manufacturing of optical subassemblies, such as TOSAs and ROSAs, face challenges in accommodating varying dimensions and configurations within constrained housings, leading to increased manufacturing costs, complexity, and production times due to the need for multiple optical component assemblies with different shapes, sizes, and mirror/filter angles to manage light paths effectively.
Innovation Solution
An optical component assembly with a vertical mounting structure that provides a fixed orientation for optical components like filters or laser diodes, allowing for a range of incident angles without modifying the physical structure of the subassembly, using a keyed shape to ensure proper alignment and reduce the need for multiple assembly configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple optical component assemblies with different shapes, sizes, and mirror/filter angles are used to manage light paths, then light path alignment is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies universality by designing a single optical component assembly structure that can accommodate multiple light path configurations through adjustable mounting angles. The housing includes multiple mounting surfaces oriented at different angles, allowing the same optical component (filter, mirror, or beam splitter) to be mounted in various orientations to manage different light path angles, eliminating the need for multiple specialized assembly designs.
Solution Approach 2:
The patent applies dynamics by making the optical component mounting angle adjustable rather than fixed. The optical component can be mounted at different angles on the housing depending on the specific light path configuration required, allowing the system to adapt to different optical arrangements without requiring completely different assembly structures.
2Volume of moving object
If optical transceiver housings are scaled down in size, then form factor is improved, but manufacturing complexity and production time increase
Solution Approach 1:
The patent reduces housing size by applying universality - a single standardized optical component assembly design serves multiple light path configurations. This eliminates the need to manufacture different assembly types for different configurations, streamlining the manufacturing process and reducing production time while maintaining compact form factor.
Solution Approach 2:
The patent merges multiple assembly configurations into a single universal design. By combining the functionality of what would otherwise require multiple different assembly types into one standardized structure with adjustable mounting options, the system achieves smaller size and faster production without sacrificing alignment precision.
3Manufacturing precision
If multiple optical component assemblies with different configurations are used, then light path management is improved, but manufacturing cost increases
Solution Approach 1:
The patent reduces manufacturing cost by applying universality - using the same optical component assembly design for multiple light path configurations. The standardized housing and mounting structures can be mass-produced using identical tooling and processes, eliminating the need for expensive custom tooling for each configuration while maintaining precise light path management through adjustable mounting angles.
Data Source
AI summary
In an embodiment, an optical component assembly is disclosed and is configured to be at least partially disposed within at least one first opening of an optical subassembly housing. The at least one optical component assembly comprising a base extending from a first end to a second end along a longitudinal axis, and a vertical mount disposed on the base and including a first surface that provides a mounting region to couple to an optical component, the first surface defining a vertical axis that extends substantially upright from the base and a horizontal axis that is angled relative to the longitudinal axis of the base at a first angle, the vertical mount further providing a channel that extends through the vertical mount, wherein the channel provides an optical pathway angled relative to the first surface at the first angle, the first angle being substantially between about 15 and 75 degrees.