WDM Subassembly Alignment via Molded Holes and Active Monitoring
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Solution Overview
Problem
Conventional coarse wavelength division multiplexing (CWDM) systems face issues with alignment tolerances during assembly, leading to low yield and optical signal misalignment, which affects transmission performance and increases optical power loss.
Innovation Solution
The introduction of a bi-directional optical subassembly with a lens array and alignment holes in a molded plastic optical device, combined with a mechanical transfer fiber patchcord and optical power meters, enables precise alignment and active power monitoring to position the light-beam collimator and multiplexer/de-multiplexer correctly, reducing signal loss and improving assembly yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional plastic optical devices are used with accumulated positioning tolerances, then assembly is easier and cost is lower, but optical alignment precision deteriorates and yield decreases
Solution Approach 1:
The patent incorporates alignment marks and positioning features directly into the molded plastic optical device during manufacturing. These preliminary alignment structures are built-in before assembly, allowing operators to quickly and accurately position the collimator and MUX/DEMUX components without requiring high-skilled alignment work, thus achieving both ease of assembly and precise optical alignment.
2Device complexity
If lens array is arranged parallel with incident light, then optical path is simplified, but transmission performance of high speed digital signals deteriorates
Solution Approach 1:
The patent employs an asymmetric lens array arrangement where the lens orientation is not parallel to the incident light direction. Instead, the lens array is positioned and oriented to receive light from the demultiplexer and transmit light to the multiplexer in a specific non-parallel configuration. This asymmetric arrangement simplifies the overall optical path while maintaining proper signal transmission performance by optimizing the light coupling geometry.
3Adaptability or versatility
If relatively long electrical circuits are used in PCB layout, then component placement flexibility is improved, but signal transmission quality deteriorates
Solution Approach 1:
The patent integrates the optical components (collimator, MUX/DEMUX, lens array) directly into or on the PCB structure, merging the optical assembly with the electrical circuit board. This integration allows the electrical circuits to be positioned closer to the optical components, significantly shortening the electrical transmission paths while maintaining placement flexibility through the modular integrated design.
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 solution reduces optical signal loss and increases the assembly yield by ensuring precise alignment of optical components, shortening electrical transmission paths, and simplifying the manufacturing process, thereby enhancing the performance and reliability of CWDM systems.
Implementation Method 1
an array of the corresponding lenses, to receive the first light beams from the demultiplexer and transmit the second light beams to the multiplexer
Implementation Method 2
a light-beam collimator configured to function or work with the multiplexer and de-multiplexer. A light beam received or transmitted by the light-beam collimator and a light beam from or to the multiplexer/de-multiplexer are collinear
Data Source
AI summary
A WDM multiplexing/demultiplexing system includes a de-multiplexer configured to separate and guide light beams from an incident ray having a plurality of wavelengths to corresponding lenses on an optical device, a multiplexer configured to guide light beams from optical transmitters having various wavelengths through the corresponding lenses on the optical device and combine the light beams, a lens array including the corresponding lenses to receive and/or transmit the light beams from or to the de-multiplexer and multiplexer, and a light beam collimator configured to function with the multiplexer and de-multiplexer. The light beams received or transmitted by the light beam collimator and the light beams transmitted or received from or to the multiplexer and de-multiplexer are collinear. The light beam collimator and multiplexer/de-multiplexer can be easily positioned to predetermined or designed positions, thereby providing light beams output through the lenses in a plastic optical device. The WDM system advantageously reduces optical signal loss, while increasing the assembly yield.