SMALL FORMED OPTICAL MODULE
Technical Field
The present invention relates to a small formed optical module, and more particularly to an optical module integrally comprising an optical transmitting module and an optical receiving module, in which pins are horizontally protruded from one surface of a package and arranged in two parallel lines or more, thereby reducing the total dimensions of the package and simultaneously easily mounting the optical module on an external circuit board .
Background Art In the course of progress of the information age, there have been required optical modules, which can transmit a large quantity of information. Such optical modules must have excellent quality themselves and also high reliability for maintaining their excellent quality for a long period of time. In order to promote the spread of the optical modules for achieving a FTTH (fiber to the home) system, the optical modules should be manufactured at low cost. Particularly, since the capacity of an optical transmitting system is recently increased, the size of an optical module mounted on the optical
transmitting system has been reduced so that the number of the optical modules mounted per unit area is increased.
Generally, methods for aligning an optical fiber and active elements (for example, a laser diode and a photo diode) of an optical module for converting an electrical signal into an optical signal or an optical signal into an electrical signal are divided into two types, i.e., an active alignment method and a passive alignment method.
In case of the active alignment method, an apparatus with resolution of less than μm unit is used for aligning the active elements and the optical fiber. This apparatus finely- moves to find the precise positions of the active elements and the optical fiber of the optical module in which an optical output is maximum. It takes a long time to use the apparatus in this method, thereby reducing mass production. Furthermore, additional components are required to perform the active alignment method, thus increasing the production cost of the optical module.
In case of the passive alignment method, the active elements and the optical fiber are precisely aligned under the condition that current is not applied to the active elements. The maximum optical output is obtained only when the position of the optical fiber and the active elements are precisely aligned before the optical fiber is substantially aligned.
Since the recent optical modules are manufactured by the active alignment method using an expensive apparatus, which can finely control the alignment in the optical fiber alignment step, it takes a long time to manufacture the optical modules, thereby increasing the cost of the modules and reducing the productivity of the modules .
As shown in Figs, la and lb, in a conventional 8 pin mini-DIL package, 8 pins are attached to the external surface of the package to be perpendicular to a module. Thus, in order to mount the package on a small formed package, the above package is rotated at an angle of 90°, and then mounted on a circuit board. Further, the circuit board is also rotated at an angle of 90° relative to the direction of the module, thus complicating the production process of the conventional 8 pin mini-DIL package.
Moreover, since 8 pins are perpendicularly attached to the side surface of the package, it is difficult to manufacture a small formed package provided with two packages, i.e., a transmitting package and a receiving package aligned in parallel.
Disclosure of the Invention
Therefore, the present invention has been made in view of the above problems, and it is an object of the present invention to provide an optical module, in which
pins are horizontally protruded from one surface of a package and arranged in two lines or more, thereby reducing the dimensions of the package and simultaneously easily connecting the optical module to an external circuit board.
In accordance with one aspect of the present invention, the above and other objects can be accomplished by the provision of an optical transmitting module comprising a substrate provided with active elements attached thereto at designated positions, and a package provided with light collection means for transferring light emitted from a light emitting element to an optical fiber and pins for intermediating an electrical signal between the package and the outside, wherein one ends of the pins installed on the package form electrical contact points with the active elements, and the other ends of the pins are horizontally protruded from one surface of the package and arranged in two lines or more.
Preferably, a protuberance with a designated shape may be formed on either one of a bottom surface of the substrate and a bottom surface of a cavity formed in the package, and a concavity corresponding the protuberance may be formed in the other one so that a passive alignment is achieved by coupling the protuberance to the concavity.
In accordance with another aspect of the present
invention, there is provided an optical receiving module comprising a substrate provided with a light receiving element attached thereto at a designated position, and a package provided with light collection means for transferring light to the light receiving element and pins for intermediating an electrical signal between the package and the outside, wherein one ends of the pins installed on the package form electrical contact points with the light receiving element, and the other ends of the pins are horizontally protruded from one surface of the package and arranged in two lines or more.
Preferably, a protuberance with a designated shape may be formed on either one of a bottom surface of the substrate and a bottom surface of a cavity formed in the package, and a concavity corresponding the protuberance may be formed in the other one so that a passive alignment is achieved by coupling the protuberance to the concavity.
In accordance with still another aspect of the present invention, there is provided an optical transreceiving module integrally comprising an optical transmitting module and an optical receiving module.
Brief Description of the Drawings The above and other objects, features and other
advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
Fig. la is a perspective view of a conventional optical module;
Fig. lb is a cross-sectional view of the conventional optical module;
Fig. 2 is a cross-sectional view of an optical transmitting module in accordance with the present invention;
Fig. 3a is a plan view of a transmitting substrate provided with active elements attached thereto;
Fig. 3b is a perspective view of the transmitting substrate provided with active elements attached thereto; Fig. 3c is a bottom view of the transmitting substrate provided with active elements attached thereto;
Fig. 4 is an exploded perspective view of an optical transmitting module in accordance with the present invention; Fig. 5 is a cross-sectional view of an optical receiving module in accordance with the present invention;
Fig. 6a is a front view of a receiving substrate provided with a light receiving element attached thereto;
Fig. 6b is a perspective view of the receiving substrate provided with a light receiving element attached
thereto;
Fig. 6c is a bottom view of the receiving substrate provided with a light receiving element attached thereto;
Fig. 7 is an exploded perspective view of an optical receiving module in accordance with the present invention; and
Fig. 8 is an exploded perspective view of an optical transreceiving module in accordance with the present invention.
Best Mode for Carrying Out the Invention
Now, preferred embodiments of the present invention will be described in detail with reference to the annexed drawings . As shown in Figs. 2 to 4 , in accordance with one preferred embodiment of the present invention, an optical transmitting module 100 comprises a package 115 for an integrated module, a substrate 101, a light emitting element 103, and a light receiving element 104. The package 115 is provided with a light collection means formed on the front surface of the package 115, and a plurality of pins
124 horizontally protruded from the rear surface of the package 115 and -arranged in at least two lines. The substrate 101 is attached to the bottom surface of a cavity formed in the package 115. The light emitting element 103
is mounted on the upper surface of the substrate 101. The light receiving element 104 serves as a sensor for controlling the optical output from the light emitting element 103. The light collection means of this embodiment includes a lens insertion hole 122 formed in the front surface of the package 115, a transmitting lens 116, and a transmitting guide pipe 118 connected to the lens insertion hole 122 and provided with a hollow 118a for receiving a transmitting ferrule 112.
It is not necessary that the position of the light collection means should be limited to the front surface of the package 115. In case the light emitting surface of the light emitting element 103 is perpendicular to the bottom surface of the package 115, the light collection means should be positioned on the upper surface of the package 115. Accordingly, it is noted that the position of the light collection means on the package 115 is changeable depending on the location of the light emitting surface of the light emitting element 103.
Generally, a ball lens is used as the transmitting lens 116. The transmitting lens 116 is installed in the lens insertion hole 122 at a position calculated in advance so that light emitted from the light emitting element 103 is concentrated on a core of an optical fiber 111.
The transmitting guide pipe 118 is provided with the hollow 118a for receiving the transmitting ferrule 112 including the optical fiber 111 installed therein. The ferrule 112 is not limited in terms of its shape. However, preferably, the ferrule 112 is formed to have a cylindrical shape. In this case, an inner diameter 118b of the hollow 118a substantially coincides with an outer diameter of the ferrule 112. Accordingly, even if the ferrule 112 is inserted into the hollow 118a in any direction, the light emitted from the light emitting element 103 is precisely concentrated on the core of the optical fiber 111.
The package 115 is not limited in terms of its material. Generally, the package 115 may be made of materials such as ceramic, metal (including alloy) or their equivalents. Preferably, a protuberance 120 having a designated shape is formed on the bottom surface of the cavity of the package 115 so as to fix the substrate l'Ol, and an opening for receiving the substrate 101 and a cover 126 are provided on the upper surface of the package 115. Here, the position of the opening is not limited, but is changeable depending on the position of the light collection means.
The protuberance 120 formed on the bottom surface of the cavity of the package 115 serves as means for precisely fixing the substrate 101 at a height determined in advance
so that the light emitted from the light emitting element 103 at the optimum position is incident on the transmitting lens 116. The protuberance 120 is not limited in terms of its shape. Accordingly, the protuberance 120 may be formed to have a shape of a V-groove or a MESA structure provided with a side wall slanted at a designated angle so that the substrate 101 is easily attached to the protuberance 120.
A plurality of the pins 124 for electrically connecting active elements (including the light emitting element and the light receiving element) to an external circuit board (not shown) are formed on one surface of the package 115. Generally, the pins 124 may be made of a lead frame. Differently from conventional pins standing in a row in a vertical direction, the pins 124 are arranged in at least two lines so that the pins 124 are horizontal with the bottom surface of the package 115.
Fig. 4 shows an optical transmitting module in accordance with one preferred embodiment of the present invention, in which the pins 124 are attached to a lower insulating plate 124b by a brazing method and an upper insulating plate 124a is stacked on the lower insulating plate 124b provided with the pins 124.
Preferably, the number of the pins 124 is minimized according to intended use, thus reducing the total dimensions of the package 115. In this embodiment of the
present invention, the number of the pins 124 in each line is at least four, thereby remarkably reducing the dimensions of the package 115. Further, the pins 124 are protruded from the rear surface of the package 115 in a horizontal direction and arranged in at least two lines, thereby allowing the package 115 to be easily mounted on an external circuit board. Moreover, the number of the pins 124 can be easily increased, thus allowing the transmitting module with increased number of electrical connections to be simply manufactured.
When the number of the pins 124 is increased, the pins 124 of a designated number are vertically arranged in at least two lines so as to remarkably reduce the total dimensions of the package, and horizontally protruded from the rear surface of the package 115 so as to allow the package 115 to be easily mounted on the external circuit board. The number of the pins 124 can be easily increased so as to integrally manufacture a transmitting module and a receiving module .
Preferably, the substrate 101 is made of a semiconductor material, for example silicon. The light emitting element 103 is attached, using solder 105, to the front area of the upper surface 101a of the substrate 101 at a constant height determined in advance so that the light is optimally incident on the
transmitting lens 116. The light receiving element 104 for sensing the strength of the light irradiated from the rear surface of the light emitting element 103 is attached, using the solder 105, to the rear area of the upper surface 101a of the substrate 101. A light reflective groove 102 with a designated shape is formed in the substrate 101 under the light receiving element 104. The light reflective groove 102 serves to reflect the light irradiated from the rear surface of the light emitting element 103 and then to allow the reflected light to be incident on the surface of the light receiving element 104. Preferably, the light reflective groove 102 is a V-shaped groove with a certain width and a thickness, which are determined by the orientation of crystals of the substrate 101. However, the shape of the light reflective groove 102 is not limited thereto.
The light emitting element 103 and the light receiving element 104 are not limited to the above- described positions. For example, the light emitting element 103 may be stacked on the light receiving element 104 so that a part of the light emitted from the light emitting element 103 is reflected and then the reflected light is incident on the upper surface of the light receiving element 104.
Contact areas 132 and 133 and patterns are provided on the substrate 101 at designated positions so that the light emitting element 103 and the light receiving element
104 are electrically connected to the pins 124 providing the connection to the external circuit board (not shown) .
A laser diode is generally used as the light emitting element 103. Preferably, an uneven structure (not shown) with a height and a size designated in advance by the orientation determined by the crystalline characteristics of single crystals may be formed on the bottom surface of the laser diode. In this case, another uneven structure with a height and a size designated in advance is formed at a constant position on the substrate 101 to which the light emitting element 103 is attached so that the uneven structure of the substrate 101 is engaged with the uneven structure of the laser diode, thereby allowing the light emitting element 103 to be mounted at a precise position on the substrate 101 without performing any alignment procedure . A photo diode is generally used as the light receiving element 104 for a monitor. The light receiving element 104 serves to control the strength of the light irradiated from the front surface of the light emitting element 103 by sensing the strength of the light incident on the surface of the light receiving element 104. A
control circuit for controlling the light receiving element 104 may be formed on an external electronic circuit board (not shown) , and detailed description thereof will thus be omitted because it is considered to be obvious to those skilled in the art.
A concavity 106 is formed in the bottom surface 101b of the substrate 101 so that a shape and a size of the concavity 106 correspond to those of the protuberance 120 formed on the bottom surface of the cavity of the package 115. The concavity 106 is not limited in terms of its forming method, but may be formed by any conventionally known etching method. ■
The passive alignment is simply achieved by coupling the concavity 106 of the substrate 101 with the protuberance 120 of the package 115. That is, since the final position of the light emitting element 103 is obtained by a method controlled in advance so that an optical axis is concentrated on the core of the optical fiber 111 in the ferrule 112, the passive alignment can be simply achieved by a single step for fixedly inserting the ferrule 112 into the package 115.
Also, the present invention also relates to a multi- optical transmitting module comprising at least two optical transmitting modules aligned in parallel and then packaged. Hereinafter, an optical receiving module in
accordance with another preferred embodiment of the present invention will be described in detail with reference to Figs. 5 to 7.
As shown in Figs. 5 to 7, in accordance with another preferred embodiment of the present invention, an optical receiving module 200 comprises a package 115' for an integrated module, a substrate 107, and a light receiving element 108. The package 115' is provided with a light collection means formed on the front surface of the package 115', and a plurality of pins 124' horizontally protruded from the rear surface of the package 115' and arranged in at least two lines. The substrate 107 is attached to the bottom surface of a cavity formed in the package 115' . The light receiving element 108 is mounted on the front surface of the substrate 107.
The light collection means of this embodiment includes a lens insertion hole 123 formed in the front surface of the package 115', a receiving lens 117,. and a receiving guide pipe 119 connected to the lens insertion hole 123 and provided with a hollow 119a for receiving a receiving ferrule 114.
In the same manner as the above light transmitting module 100, it is not necessary that the position of the light collection means should be limited to the front surface of the package 115' .
Generally, a ball lens is used as the receiving lens 117. The receiving lens 117 is installed in the lens insertion hole 123 at a position calculated in advance so that light emitted from an optical fiber 113 is concentrated on an acceptance core of the light receiving element 108.
The receiving guide pipe 119 is provided with the hollow 119a for receiving the receiving ferrule 114 including the optical fiber 113 installed therein. The ferrule 114 is not limited in terms of its shape. However, preferably, the ferrule 114 is formed to have a cylindrical shape. In this case, an inner diameter 119b of the hollow 119a substantially coincides with an outer diameter of the ferrule 114. Accordingly, even if the ferrule 114 is inserted into the hollow 119a in any direction, the light is precisely concentrated on the acceptance core of the light receiving element 108.
A protuberance 121 having a designated shape is formed on the bottom surface of the cavity of the package 115' so as to fix the substrate 107, and an opening for receiving the substrate 107 and a cover 126' are provided on the upper surface of the package 115' . Here, in the same manner as the above light transmitting module 100, the position of the opening in the optical receiving module 200 is not limited, but is changeable depending on the position
of the light collection means.
The protuberance 121 formed on the bottom surface of the cavity of the package 115' serves as means for precisely fixing the substrate 107 at a height determined in advance so that the light emitted from the optical fiber 113 is concentrated on the acceptance core of the receiving lens 117. The protuberance 121 is not limited in terms of its shape. Accordingly, the protuberance 121 may be formed to have a shape of a V-groove or a MESA structure provided with a side wall slanted at a designated angle so that the substrate 107 is easily attached to the protuberance 121.
A plurality of the pins 124' for electrically connecting the light receiving element 108 to an external circuit board (not shown) are formed on one surface of the package 115' . Generally, the pins 124' may be made of a lead frame. Differently from conventional pins standing in a row vertically protruded from the surface of the package, the pins 124' are arranged in at least two lines so that the pins 124' are horizontal with the bottom surface of the package 115' . The constitution of the pin 124' of the optical receiving module 200 is substantially the same as that of the optical transmitting module 100 shown in Fig. 4, and a detailed description thereof will thus be omitted.
Preferably, the number of the pins 124' is minimized according to intended use, thus reducing the total
dimensions of the package 115' . In this embodiment of the present invention, the number of the pins 124' in each line is at least four, thereby remarkably reducing the dimensions of the package 115' . Further, the pins 124' are protruded from the rear surface of the package 115' in a horizontal direction and arranged in at least two lines, thereby allowing the package 115' to be easily mounted on an external circuit board. Moreover, the number of the pins 124' can be easily increased, thus allowing the receiving module with increased number of electrical connections to be simply manufactured.
When the number of the pins is further increased, the pins of a designated number are vertically arranged in at least two lines so as to remarkably reduce the total dimensions of the package, and horizontally protruded from the rear surface of the package so as to allow the package to be easily mounted on the external circuit board. The number of the pins is easily increased so as to integrally manufacture a transmitting module and a receiving module.
The substrate 107 is not limited in terms of its material, but may be made of a ceramic material. The light receiving element 108 is attached to the front surface 107a of the substrate 107 by solder 109, and a contact area 134 is provided on the substrate 107 at a designated position
so that the light receiving element 108 is electrically connected to 'the pins 124' .
A photo diode is preferably used as the light receiving element 108. The light receiving element 108 is fixedly located at a designated position on the substrate 107 so that the light receiving element 108 and a central axis of the receiving lens 117 are arranged in a straight line.
A concavity 110 is formed in the bottom surface 107b of the substrate 107 so that a shape and a size of the concavity 110 correspond to those of the protuberance 121 formed on the bottom surface of the cavity of the package 115' . The concavity 110 is not limited in terms of its forming method, but may be formed by means of a mold in manufacturing the substrate 107 or by a separate cutting step.
The passive alignment is simply achieved by coupling the concavity 110 of the substrate 107 with the protuberance 121 of the package 115'. That is, since the light receiving element 108 is fixed to the front surface of the substrate 107 by a method controlled in advance so that the light emitted from the optical fiber 113 is concentrated on the acceptance core of the light receiving element 108, the passive alignment can be simply achieved by a single step for fixedly inserting the ferrule 114 into
the package 115' .
The present invention also relates to a multi-optical receiving module comprising at least two optical receiving modules aligned in parallel and then packaged. Hereinafter, an optical transreceiving module 300 integrally comprising the above-described optical transmitting and receiving modules 100 and 200 in accordance with another preferred embodiment of the present invention will be described in detail with reference to Fig. 8.
As shown in Fig. 8, as described above, the transmitting and receiving guide pipes 118 and 119 connected to a pair of the lens insertion holes 122 and 123 are formed on the front surface of the package 115, and the protuberances 120 and 121 having a designated shape are formed on the bottom surfaces of cavities A and B divided by a diaphragm 305 in the package 115. The concavities 106 and 110 are formed in the bottom surfaces of transmitting and receiving substrates 101 and 107 so that shapes and sizes of the concavities 106 and 110 correspond to those of the protuberances 120 and 121 formed on the bottom surfaces of the cavities A and B of the package 115, thus aligning the bottom surfaces of transmitting and receiving substrates 101 and 107 precisely in the cavities A and B of the package 115.
An opening for receiving the transmitting and receiving substrates 101 and 107 is formed in the upper surface of the package 115, and the cover 126' is provided on the upper surface of the package 115. The above-described optical transreceiving module 300 is electrically connected to a transreceiving electronic circuit board (not shown) for operating and controlling the active elements installed in the optical transmitting module 100 and the optical receiving module 200. The present invention also relates to a multi-optical transreceiving module comprising at least two optical transreceiving modules aligned in parallel and then packaged.
Hereinafter, a process for manufacturing 'the above optical transreceiving module will be described in detail.
An electrical connection step such as wire bonding is omitted because it is considered to be obvious to those skilled in the art.
The package 115 for an integrated module is seated on a stage (not shown) . The silicon substrate 101 provided with the laser diode 103 and the photo diode 104 for a monitor is picked up, and then mounted in the cavity A of the package 115. Here, the silicon substrate 101 is aligned at a precise position on the bottom surface of the package 115 by the concavity 106 provided with the slanted
side wall formed in the bottom surface of the silicon substrate 101 and the flat bottom surface with a rectangular shape, and the MESA structure 120 provided with the slanted side wall formed on the bottom surface of the cavity A of the package 115 so that the shape and size of the concavity 106 correspond to those of the MESA structure 120. Solder having a designated melting point is coated on the upper surface of the MESA structure 120.
In the same manner, the ceramic block 107 provided with the photo diode 108 is picked up, and then mounted in the other cavity B of the package 115. Here, the ceramic block 107 is aligned at a precise position on the bottom surface of the package 115 by the concavity 110 provided with the slanted side wall formed in the bottom surface of the ceramic block 107 and the flat bottom surface with a rectangular shape, and the MESA structure 121 provided with the slanted side wall formed on the bottom surface of the cavity B of the package 115 so that the shape and size of the concavity 110 correspond to those of the MESA structure 121. Also, solder having a designated melting point is coated on the upper surface of the MESA structure 121.
The stage is heated so that the solder (not shown) coated on the upper surfaces of the MESA structures 120 and 121 is melted, thus fixing the silicon substrate 101 for
transmitting light and the ceramic block 107 for receiving light at precise positions in the package 115.
After the silicon substrate 101 for transmitting light and the ceramic block 107 for receiving light are fixed in the package 115, the cover 126 is fixed to the upper surface of the package 115 by electric welding under a nitrogen atmosphere .
After the mounting of the silicon substrate 101 for transmitting light and the ceramic block 107 for receiving light in the cavities A and B is completed, the transmitting ferrule 112 provided with the transmitting optical fiber 111 and the receiving ferrule 114 provided with the receiving optical fiber 113 are inserted into the hollows of the transmitting and receiving guide pipes 118 and 119 prepared in pair and attached to the front surface of the package 115, and then fixed to the hollows by laser welding, or etc.
Industrial Applicability As apparent from the above description, the present invention provides an optical module, in which pins are horizontally protruded from one surface of a package in parallel with an optical axis and arranged in two lines or more, thereby being easily mounted on an external circuit board. The number of the pins is properly adjusted,
thereby allowing the total dimensions of the package to be reduced. Since the pins protruded from one surface of the package are arranged in two lines or more, an optical transmitting module and an optical receiving module can be integrally packaged.
Further, the passive alignment is achieved without the operation of a light emitting or receiving element. Moreover, since the optical module is manufactured under the condition that the inner components are aligned in advance, it is possible to reduce the time taken in aligning the components .
Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.