Optical module and manufacturing method therefor

Claim 2

An optical module comprising: a housing (4) having an opening (2) extending from an outer side to an inner side of said housing (4) and having an outer surface around said opening (2); a main ring (16) having a substantially central hole (16A) and fixed to said housing (4) so that an end surface of said main ring (16) is in close contact with said outer surface of said housing (4); a ferrule fixed to said main ring (16) under a condition where said ferrule is inserted in said substantially central hole (16A) of said main ring (16); an optical fiber (8) fixed to said ferrule under a condition where said optical fiber (8) is inserted in a center hole of said ferrule; a reinforcement ring (18) fixed to said main ring (16) and said ferrule so as to cover said ferrule in Juxtaposed relationship to said main ring (16), a fixing point between said reinforcement ring (18) and said main ring (16) being positioned outside of a fixing point between said reinforcement ring (18) and said ferrule; and an optical device provided in said housing (4) and adapted to be optically coupled with said optical fiber (8).

Claim 3

An optical module according to claim 1, wherein said ferrule is cylindrical in shape, and inner diameters of said main ring (16) and said reinforcement ring (18) are substantially equal to an outer diameter of said ferrule.

Claim 4

An optical module according to claim 1, wherein said optical device is selected from a photo-electric conversion element, an electric-photo conversion element, and an optical wave-guide chip.

Claim 5

An optical module according to claim 1, wherein said optical fiber (8) is fixed to said ferrule so that an end portion of said optical fiber (8) projects through said opening (2) of said housing (4) into said housing (4), said end portion of said optical fiber (8) having a tapering, spherical end such that a diameter of said optical fiber (8) at said end continuously decreases toward a tip of said end and a portion near said tip is substantially semispherical, said optical device being located on a geometrical center line of said optical fiber (8).

Claim 6

An optical module according to claim 1, wherein said optical fiber (8) is fixed to said ferrule so that an end portion of said optical fiber (8) projects through said opening (2) of said housing (4) into said housing (4), said end portion of said optical fiber (8) having an end surface inclined with respect to a surface perpendicular to a geometrical center line of said optical fiber (8), said optical device being located on an optical path of light reflecting from said end surface of said optical fiber (8).

Claim 7

An optical module according to claim 5, wherein said optical device comprises a light receiving element (120) of a back surface incident type having an electrode surface and a lens integrally provided on another surface opposite to said electrode surface, said light receiving element (120) being mounted by flip chip bonding to a conductor pattern on a printed circuit board (44) accommodated in said housing (4).

Claim 8

An optical module according to claim 1, wherein said optical fiber (8) is fixed to said ferrule so that an end portion of said optical fiber (8) is located in said ferrule, said optical module further comprising a lens provided in said ferrule so as to be opposed to said end portion of said optical fiber (8).

Claim 9

A manufacturing method for an optical module, comprising: the first step of inserting a ferrule having a center hole in which an optical fiber (8) is inserted and fixed, into a substantially central hole (16A) of a main ring (16), bringing an end surface of said main ring (16) into close contact with an outer surface of a housing (4) around an opening (2) extending from an outer side to an inner side of said housing (4), and adjusting a relative positional relationship between said ferrule and said main ring (16) and a relative positional relationship between said main ring (16) and said housing (4) under a condition where said ferrule is inserted in said substantially central hole (16A) of said main ring (16) and said end surface of said main ring (16) is in close contact with said outer surface of said housing (4); the second step of fixing said ferrule to said main ring (16) and fixing said main ring (16) to said housing (4); and the third step of fixing a reinforcement ring (18) to said ferrule and said main ring (16) so that said reinforcement ring (18) covers said ferrule in juxtaposed relationship to said main ring (16), a fixing point between said reinforcement ring (18) and said main ring (16) being positioned outside of a fixing point between said ferrule and said main ring (16).

Claim 10

A manufacturing method for an optical module, comprising: the first step of inserting a ferrule having a center hole in which an optical fiber (8) is inserted and fixed, into a substantially central hole (16A) of a main ring (16), bringing an end surface of said main ring (16) into close contact with an outer surface of a housing (4) around an opening (2) extending from an outer side to an inner side of said housing (4), and adjusting a relative positional relationship between said ferrule and said main ring (16) and a relative positional relationship between said main ring (16) and said housing (4) under a condition where said ferrule is inserted in said substantially central hole (16A) of said main ring (16) and said end surface of said main ring (16) is in close contact with said outer surface of said housing (4); the second step of fixing said ferrule to said main ring (16) and fixing said main ring (16) to said housing (4); and the third step of fixing a reinforcement ring (18) to said ferrule and said main ring (16) so that said reinforcement ring (18) covers said ferrule in juxtaposed relationship to said main ring (16), a fixing point between said reinforcement ring (18) and said main ring (16) being positioned outside of a fixing point between said ferrule and said main ring (16).

Claim 11

A manufacturing method according to claim 8, wherein adjustment of said relative positional relationships in said first step is effected by measuring an optical coupling efficiency between said optical fiber (8) and an optical device provided in said housing (4), and obtaining a maximum value of said optical coupling efficiency measured.

Claim 12

A manufacturing method according to claim 8, wherein fixation of said ferrule to said main ring (16) in said second step, fixation of said main ring (16) to said housing (4) in said second step, and fixation of said reinforcement ring (18) to said ferrule and said main ring (16) in said third step are effected by laser welding.

Claim 13

A manufacturing method according to claim 10, wherein: a position of irradiation of laser in said laser welding of said ferrule and said main ring (16) comprises a plurality of points lying on an edge of a contact surface between said ferrule and said main ring (16) on an opposite side of said housing (4); a position of irradiation of laser in said laser welding of said main ring (16) and said housing (4) comprises a plurality of points lying on an outer circumferential edge of a contact surface between said main ring (16) and said housing (4); a position of irradiation of laser in said laser welding of said reinforcement ring (18) and said main ring (16) comprises a plurality of points lying on an outer circumferential edge of a contact surface between said reinforcement ring (18) and said main ring (16); and a position of irradiation of laser in said laser welding of said reinforcement ring (18) and said ferrule comprises a plurality of points lying on an edge of a contact surface between said reinforcement ring (18) and said ferrule on an opposite side of said housing (4).

Claim 14

A manufacturing method according to claim 11, wherein said plurality of points in each laser welding are equally spaced on a circumference.

Claim 15

A manufacturing method according to claim 11, wherein said laser welding of said main ring (16) and said housing (4) in said second step is effected under a condition where said main ring (16) is pressed against said housing (4) by a ring-shaped press jig (36, 36') having an end portion formed with a plurality of recesses (40) corresponding to said plurality of points in said laser welding of said ferrule and said main ring (16), said plurality of recesses (40) of said ring-shaped press jig (36, 36') permitting laser beams to pass therethrough in said laser welding of said ferrule and said main ring (16).

Claim 16

A manufacturing method according to claim 13, wherein a width and a depth of each recess (40) and an angle of inclination of a bottom surface (40a) of each recess (40) are set according to a shape and an angle of irradiation of each laser beam so that each laser beam is not cut off by said ring-shaped press jig (36, 36') in performing said laser welding of said ferrule and said main ring (16).

Claim 17

A manufacturing method according to claim 13, further comprising means provided at another end portion of said ring-shaped press jig (36') on an opposite side of said main ring (16) for temporarily fixing said ferrule to said ring-shaped press jig (36'), wherein movement of said ferrule in a longitudinal direction thereof is limited by said temporarily fixing means in performing said laser welding of said ferrule and said main ring (16).

Claim 18

A manufacturing method according to claim 13, wherein said ring-shaped press jig (36, 36') used in said second step is used also as said reinforcement ring (18) in said third step.

Claim 19

A manufacturing method according to claim 8, wherein said ferrule comprises a first pipe (50) made of metal and a second pipe (52) made of ceramic, said first pipe (50) being formed with an axial hole (50A) having a diameter slightly larger than an outer diameter of a cover (48) covering said optical fiber (8), said second pipe (52) being formed with an axial hole (52A) as said center hole having a diameter slightly larger than an outer diameter of said optical fiber (8), said second pipe (52) being inserted in said axial hole (50A) of said first pipe (50) so as to project from an end surface of said first pipe (50); said manufacturing method further comprising the steps of: inserting said second pipe (52) into said axial hole (50A) of said first pipe (50) and sealing a clearance between said first pipe (50) and said second pipe (52) by using a brazing material having a relatively high melting point; inserting said optical fiber (8) and said cover (48) into said axial hole (52A) and said axial hole (50A), respectively, and sealing a clearance between said optical fiber (8) and said second pipe (52) by using a soldering material having a relatively low melting point; and sealing a clearance between said first pipe (50) and said main ring (16) and a clearance between said main ring (16) and said housing (4) by laser welding.

Claim 20

A manufacturing method according to claim 17, wherein a main component of said brazing material comprises silver, and said soldering material comprises an eutectic alloy of gold and tin.

Claim 21

An optical module comprising: a housing (4) having an opening (2) extending from an outer side to an inner side of said housing (4) and having an outer surface around said opening (2); a ring (6) having a substantially central hole (6A) and fixed to said housing (4) so that an end surface of said ring (6) is in close contact with said outer surface of said housing (4); a ferrule (10') fixed to said ring (6) under a condition where said ferrule (10') is inserted in said substantially central hole (6A) of said ring (6); an optical fiber (8) fixed to said ferrule (10') under a condition where said optical fiber (8) is inserted in a center hole of said ferrule (10'); and an optical device provided in said housing (4) and adapted to be optically coupled with said optical fiber (8); wherein said ferrule comprises a first pipe (50) made of metal and a second pipe (52) made of ceramic, said first pipe (50) being formed with an axial hole (50A) having a diameter slightly larger than an outer diameter of a cover (48) covering said optical fiber (8), said second pipe (52) being formed with an axial hole (52A) as said center hole having a diameter slightly larger than an outer diameter of said optical fiber (8), said second pipe (52) being inserted in said axial hole (50A) of said first pipe (50) so as to project from an end surface of said first pipe (50).

Claim 22

An optical module comprising: a housing (4) having an opening (2) extending from an outer side to an inner side of said housing (4) and having an outer surface around said opening (2); a ring (6) having a substantially central hole (6A) and fixed to said housing (4) so that an end surface of said ring (6) is in close contact with said outer surface of said housing (4); a ferrule (10') fixed to said ring (6) under a condition where said ferrule (10') is inserted in said substantially central hole (6A) of said ring (6); an optical fiber (8) fixed to said ferrule (10') under a condition where said optical fiber (8) is inserted in a center hole of said ferrule (10'); and an optical device provided in said housing (4) and adapted to be optically coupled with said optical fiber (8); wherein said ferrule comprises a first pipe (50) made of metal and a second pipe (52) made of ceramic, said first pipe (50) being formed with an axial hole (50A) having a diameter slightly larger than an outer diameter of a cover (48) covering said optical fiber (8), said second pipe (52) being formed with an axial hole (52A) as said center hole having a diameter slightly larger than an outer diameter of said optical fiber (8), said second pipe (52) being inserted in said axial hole (50A) of said first pipe (50) so as to project from an end surface of said first pipe (50).

Claim 23

An optical module according to claim 19, wherein: a clearance between said first pipe (50) and said second pipe (52) is sealed by a brazing material having a relatively high melting point; a clearance between said optical fiber (8) and said second pipe (52) is sealed by a soldering material having a relatively low melting point; and a clearance between said first pipe (50) and said ring (6) and a clearance between said ring (6) and said housing (4) are sealed by laser welding.