Welding Assembly Aligning TOSA Modules
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Solution Overview
Problem
The challenge in designing high-speed optical transceivers is maintaining optical efficiency and thermal management while scaling down the size of optical subassembly modules, as existing attachment and alignment approaches are error-prone and affect manufacturing yield due to reduced tolerances.
Innovation Solution
A welding assembly with a mechanical grabber and alignment member is used to couple and align the TOSA module with the subassembly housing, providing temporary electrical coupling and ensuring nominal optical performance through precise alignment and welding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing attachment and alignment approaches are used to couple TOSA modules, then the manufacturing process is simpler, but alignment precision and manufacturing yield deteriorate due to reduced tolerances in compact modules
Solution Approach 1:
The patent introduces a welding assembly as an intermediary device that includes a clamp body for holding the TOSA module, an alignment member with alignment features for precise positioning, and a welding member for permanent attachment. This intermediary system enables high-precision alignment and attachment that overcomes the limitations of direct attachment methods, particularly in compact modules where tolerances are reduced.
2Volume of moving object
If the size of optical subassembly modules is scaled down to provide higher speeds in smaller modules, then compactness is improved, but optical efficiency and manufacturing yield worsen due to reduced tolerances and increased error-proneness
Solution Approach 1:
The welding assembly performs preliminary alignment actions before permanent attachment. The alignment member with its alignment features (such as alignment pins, grooves, or flat surfaces) pre-positions the TOSA module with high precision relative to the optical components. This preliminary alignment ensures that even in compact modules with reduced tolerances, the optical components are correctly positioned before welding occurs, preventing misalignment errors.
Solution Approach 2:
The welding assembly acts as an intermediary system that decouples the challenges of miniaturization from the requirements of precision alignment. By introducing this intermediate device with built-in alignment features, the system maintains manufacturing precision independent of module size, allowing compact modules to achieve the same alignment accuracy as larger modules.
3Manufacturing precision
If conventional welding and attachment methods are used, then the process is faster, but alignment accuracy and optical performance worsen due to inability to maintain precise positioning
Solution Approach 1:
The welding assembly merges multiple functions into a single integrated device: the clamp body for holding, the alignment member for positioning, and the welding member for permanent attachment. This combination allows the system to perform alignment and attachment in a coordinated manner, maintaining precision while improving efficiency compared to separate alignment and welding operations.
Solution Approach 2:
The alignment features on the alignment member perform preliminary positioning actions before the welding process begins. This ensures that the TOSA module is precisely aligned with optical components before permanent attachment, eliminating the need for post-welding adjustments and rework, thereby maintaining both precision and productivity.
Data Source
AI summary
In accordance with an embodiment, a welding assembly is disclosed that allows for a laser assembly to be coupled into a socket of the same and held at a fixed position, e.g., by a mechanical grabber of a welding system. The mechanical grabber may then travel along one or more axis to bring the TOSA module into mechanical alignment with an opening of an associated optical subassembly housing. The welding assembly may further include an alignment member that provides one or more alignment contact surfaces configured to be brought directly into contact with a surface of the associated subassembly housing. When the one or more alignment contact surfaces are “flush” with the surface of the subassembly housing the emission face of the TOSA module is substantially parallel, and by extension, optically aligned with the opening of the associated subassembly housing.