US20030162003A1 - Manufacturing system using solder self-alignment with optical component deformation fine alignment - Google Patents
Manufacturing system using solder self-alignment with optical component deformation fine alignment Download PDFInfo
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- US20030162003A1 US20030162003A1 US10/391,835 US39183503A US2003162003A1 US 20030162003 A1 US20030162003 A1 US 20030162003A1 US 39183503 A US39183503 A US 39183503A US 2003162003 A1 US2003162003 A1 US 2003162003A1
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- Prior art keywords
- alignment
- optical
- bench
- optical components
- solder
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/42—Coupling light guides with opto-electronic elements
- G02B6/4201—Packages, e.g. shape, construction, internal or external details
- G02B6/4219—Mechanical fixtures for holding or positioning the elements relative to each other in the couplings; Alignment methods for the elements, e.g. measuring or observing methods especially used therefor
- G02B6/422—Active alignment, i.e. moving the elements in response to the detected degree of coupling or position of the elements
- G02B6/4226—Positioning means for moving the elements into alignment, e.g. alignment screws, deformation of the mount
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/30—Assembling printed circuits with electric components, e.g. with resistor
- H05K3/303—Surface mounted components, e.g. affixing before soldering, aligning means, spacing means
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/42—Coupling light guides with opto-electronic elements
- G02B6/4201—Packages, e.g. shape, construction, internal or external details
- G02B6/4219—Mechanical fixtures for holding or positioning the elements relative to each other in the couplings; Alignment methods for the elements, e.g. measuring or observing methods especially used therefor
- G02B6/4228—Passive alignment, i.e. without a detection of the degree of coupling or the position of the elements
- G02B6/4232—Passive alignment, i.e. without a detection of the degree of coupling or the position of the elements using the surface tension of fluid solder to align the elements, e.g. solder bump techniques
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/24—Coupling light guides
- G02B6/42—Coupling light guides with opto-electronic elements
- G02B6/4201—Packages, e.g. shape, construction, internal or external details
- G02B6/4219—Mechanical fixtures for holding or positioning the elements relative to each other in the couplings; Alignment methods for the elements, e.g. measuring or observing methods especially used therefor
- G02B6/4236—Fixing or mounting methods of the aligned elements
- G02B6/4238—Soldering
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/20—Details of printed circuits not provided for in H05K2201/01 - H05K2201/10
- H05K2201/2036—Permanent spacer or stand-off in a printed circuit or printed circuit assembly
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
- H05K2203/01—Tools for processing; Objects used during processing
- H05K2203/0186—Mask formed or laid on PCB, the mask having recesses or openings specially designed for mounting components or body parts thereof
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.
- Y10T29/4913—Assembling to base an electrical component, e.g., capacitor, etc.
- Y10T29/49144—Assembling to base an electrical component, e.g., capacitor, etc. by metal fusion
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49764—Method of mechanical manufacture with testing or indicating
- Y10T29/49769—Using optical instrument [excludes mere human eyeballing]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49764—Method of mechanical manufacture with testing or indicating
- Y10T29/49771—Quantitative measuring or gauging
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49764—Method of mechanical manufacture with testing or indicating
- Y10T29/49778—Method of mechanical manufacture with testing or indicating with aligning, guiding, or instruction
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49826—Assembling or joining
- Y10T29/49861—Sizing mating parts during final positional association
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/53—Means to assemble or disassemble
- Y10T29/5313—Means to assemble electrical device
- Y10T29/53174—Means to fasten electrical component to wiring board, base, or substrate
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24917—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including metal layer
Definitions
- Solder self-alignment is a technique for aligning devices, such as semiconductor chips, to carriers, such as packages.
- Solder is predeposited on the carriers typically to lithographic precision to form bond pads.
- the devices are placed on bond pads to form a precursor structure, which is then placed in a solder reflow oven where the solder pads are heated to a liquidous state. The resulting surface tension in the liquid solder pulls the devices into alignment with the bond pads and thus the carriers.
- solder self-alignment has also been used in optoelectronic device manufacture.
- optical components such as an active device, e.g., laser chip, or passive devices, e.g., lenses or filters, are placed on bond pads, which have been predeposited on optical benches or submounts.
- active device e.g., laser chip
- passive devices e.g., lenses or filters
- bond pads which have been predeposited on optical benches or submounts.
- these precursor structures are placed in a solder reflow oven where the solder is heated to a liquidous state.
- the optical components are then pulled into alignment by surface tension on the optical benches.
- optical component alignment using solder self-alignment techniques is effective to align the optical components relative to the benches to accuracies of about 10 micrometers ( ⁇ m).
- ⁇ m micrometers
- other passive alignment processes such as registration features and/or installation by pick-and-place machines, in high volume manufacturing processes.
- the advantage is that it can be implemented quickly using manual placement of the optical components on the solder pads.
- solder self-alignment is its alignment accuracy limitation.
- Many carrier-class fiber optic components require alignment accuracy of a few micrometers to sub-micrometer accuracy.
- Existing solder alignment processes generally cannot achieve such tolerances.
- the present invention is directed to a process for assembling micro-optical systems, such as optoelectronic and/or fiber optic components. It uses solder self-alignment to achieve a coarse, passive alignment of optical components relative to the optical bench. The fine, final alignment, however, is performed using plastic deformation of the optical components to thereby improve the alignment of the optical components. As a result, alignment accuracies of a few micrometers to sub-micrometer are attainable, if required.
- the invention features a process for assembling micro-optical systems.
- This process comprises depositing pads at locations on optical benches determined by intended engagement points between optical components and the optical benches.
- the optical components are then placed on these solder pads.
- a solder reflow process is then performed to join the optical components to the optical benches using the solder pads.
- self-alignment of the optical components is allowed using the solder surface tension.
- the alignment of the optical components is improved by plastically deforming the components on the benches.
- the solder reflow process results in the positioning of the optical components to accuracies of between 2 and 10 micrometers. Then, the final step of improving the alignment using plastic deformation results in the alignment of the components to about 1 micrometer or better.
- the plastic deformation is performed in an active alignment process. Specifically, optical signals are directed to the optical component and the optical components deformed in response to the optical signals after interaction with the optical components.
- the step of plastically deforming the optical components comprises deforming the optical components in response to metrology data describing in the positions of the optical components relative to the benches and also so in response to the desired positions of the optical components.
- solder or metal pads are predeposited on feet of the optical components.
- solder preforms can be further placed between the optical components and the solder pads of the benches.
- the optical components are placed on the solder pads manually. Vacuum wands are preferably used to manipulate the small optical components.
- pick-and-place machines are used, such as flip chip bonders, to place the optical components on the benches.
- lateral registration features are helpful in some implementations to facilitate the initial placement of the optical components on the pads. Registration features can also be further used to control the subsequent self-alignment process. These registration features are formed on the bench surface in one implementation. Alternatively, separate templates are used.
- magnetic fixturing is used at least after the placement of the optical components on the optical bench to hold the optical components on the optical bench. This is typically accomplished by providing optical components that include mounting structures that are made from a ferromagnetic material, such as nickel or iron. A magnetic field is oriented at least partially orthogonal to the bench in a downward direction toward the bench.
- the invention also features an unpopulated bench precursor structure.
- This structure comprises a bench.
- the benches are manufactured from a temperature stable substance such as silicon or beryllium nitride, or aluminum nitride.
- the pads are predeposited on the bench at locations determined by desired engagement points between the optical components and the optical bench. Registration features are further provided on the bench in or near the solder pads for supporting the optical components at a predetermined position vertically on the bench.
- FIG. 1 is a flow diagram illustrating one manufacturing process using solder self-alignment with optical component deformation fine alignment, according to the present invention
- FIG. 2A is a perspective view showing an unpopulated optical bench with predeposited pads forming an unpopulated optical bench precursor structure with the optical components schematically shown ready for installation or placement on the pads of the bench, according to the present invention
- FIG. 2B is a perspective view of a bench template according to the present invention.
- FIG. 3 is a perspective view showing the populated optical bench
- FIG. 4 is a detailed perspective view showing the interaction between the bench spacers and optical components after solder reflow.
- FIG. 5 shows the fine alignment process in which the optical components are plastically deformed to thereby improve the alignment of the system.
- FIG. 1 is a flow diagram illustrating an optical system manufacturing process embodying the principles of the present invention.
- optical components are assembled from optical mounting structures and optical elements in step 110 as required. This component level assembly is avoided in some implementations, however, by monolithic fabrication of the components.
- metal or other material is deposited on the targeted optical bench in step 112 to form the bond pads.
- the bond pad is defined by a gold layer.
- a gold layer For some optical benches, actually a multi layer structure is used, such as a titanium or chromium adhesion is layer, a nickel or platinum barrier layer, and a gold layer. This gold layer defines the bond pad.
- FIG. 2A illustrates the result of the subassembly step.
- the optical components are divided into two classes: 1) high precision alignment components 25 ; 2) and low precision alignment components 35 .
- the high precision components 25 require additional alignment beyond that available using only solder self-alignment.
- these components include lenses 1 , fiber endfaces fe, and micro electromechanical systems (MEMS) devices such tunable filters tf.
- MEMS micro electromechanical systems
- the high precision components 25 each comprise an optical component mounting structure 12 and an optical element 14 .
- the optical component mounting structures are manufactured using the LIGA process.
- LIGA is a German acronym that stands for lithography, plating, and molding.
- the optical elements 14 include lenses, which are manufactured using an etching and/or mass transport processes in gallium phosphide or silicon, and MEMS devices.
- the optical elements 14 are solder bonded to the respective mounting structures 12 .
- the components are monolithically formed using, for example, deep RIE and metal deposition.
- the mounting structures or at least their feet are coated to facilitate the solder bonding process.
- they are gold coated.
- Solder can also be predeposited onto the feet of the mounting structures.
- solder or metal material is deposited on the optical bench 5 to thereby form the bond pads 40 on an unpopulated optical bench precursor structure. These pads 40 are deposited on the bench at locations determined by the desired engagement points between the optical components 25 , 35 and the optical bench 5 .
- spacers 42 are further provided on the bench 5 , in or near the solder pads 40 for supporting the optical components 25 , 35 at predetermined positions vertically relative to the bench. This further confines the movement and alignment of the optical components in the vertical dimension, with the lateral dimensions being determined by the surface tension during the reflow process as detailed below.
- the optical components are placed on the optical bench, as illustrated in FIG. 2 by the arrows.
- the optical components are placed manually on the solder pads using, for example, vacuum wands.
- the optical components are placed on the solder pads using a pick-and-place machine.
- Flip chip bonders are capable for the required precision placement.
- the optical components 25 are tack bonded to the bond pads of the optical bench.
- FIG. 2B illustrates a placement jig or template 70 that is used to facilitate the placement of the optical components on the bench 5 .
- the template 70 is aligned over the bench 5 .
- the template 70 has through-holes or registration features 72 into which the optical component are inserted so that they are aligned over the bond pads on the bench 5 .
- the jig 70 can be manufactured from graphite or silicon.
- FIG. 3 illustrates the result of the placement step 114 , with the optical bench 5 having received the optical components 25 , 35 .
- the bench with optical components is placed in a solder reflow oven or other reflow device.
- Ovens are useful because they create the optimum solder reflow environments in which the solder is raised to a liquidous temperature in an forming gas atmosphere so that the components are simultaneously bonded to the optical bench while the solder surface tension pulls the optical components into alignment relative to the solder pads. Typically, this can align the optical components on the optical benches to accuracies of 2 to 10 micrometers.
- FIG. 4 illustrates the result of the reflow process in which the various optical components 25 , 35 are solder bonded to the bench 5 .
- This detailed view further illustrates the operation of the spacers 42 .
- spacers 42 function to act is stand-offs between the bench 5 and the mounting structures 12 so that they are fixed at a predetermined height above the bench even after solidification, i.e., shrinkage, of the solder in the bond pads 40 .
- step 118 active and/or passive fine alignment is performed by plastic deformation of the high precision optical components 25 .
- jaws J 1 , J 2 of an alignment system engage the individual optical components 25 and plastically deform the mounting structures 12 of the optical components to improve their alignment relative to the optical system 10 .
- this alignment can be an active alignment process where an optical signal generator 210 is used to generate an optical signal that interacts with the optical element (lens) 14 of the optical component 25 . The alignment is then performed relative to the optical signal after interaction with the optical component.
- metrology data are collected which indicates the actual positions of the optical components 25 on the optical bench 5 .
- the alignment system then plastically deforms the optical components 25 relative to this metrology data and additional data that dictate the desired positions of the optical components relative to the optical benches and/or relative to other optical components.
Abstract
A process for assembling micro-optical systems, such as optoelectronic and/or fiber optic components uses solder self-alignment to achieve a coarse, passive alignment of optical components relative to the optical bench. The fine, final alignment is performed using plastic deformation of the optical components to thereby improve the alignment of the optical components. As a result, the sub-micrometer alignment accuracies are attainable, if required.
Description
- This application is a divisional application of U.S. patent application Ser. No. 09/802,731, filed Mar. 8, 2001, by Walid A. Atia, Steven D. Conover, Eric E. Fitch Sean P. O'Connor and Randal A. Murdza, entitled MANUFACTURING SYSTEM USING SOLDER SELF-ALIGNMENT WITH OPTICAL COMPONENT DEFORMATION FINE ALIGNMENT. The teachings of this application are incorporated herein in their entirety by this reference.
- Solder self-alignment is a technique for aligning devices, such as semiconductor chips, to carriers, such as packages. Solder is predeposited on the carriers typically to lithographic precision to form bond pads. The devices are placed on bond pads to form a precursor structure, which is then placed in a solder reflow oven where the solder pads are heated to a liquidous state. The resulting surface tension in the liquid solder pulls the devices into alignment with the bond pads and thus the carriers.
- Solder self-alignment has also been used in optoelectronic device manufacture. In these applications, optical components, such as an active device, e.g., laser chip, or passive devices, e.g., lenses or filters, are placed on bond pads, which have been predeposited on optical benches or submounts. Then, these precursor structures are placed in a solder reflow oven where the solder is heated to a liquidous state. The optical components are then pulled into alignment by surface tension on the optical benches.
- With well-characterized processes, optical component alignment using solder self-alignment techniques is effective to align the optical components relative to the benches to accuracies of about 10 micrometers (μm). As a result, it competes with other passive alignment processes, such as registration features and/or installation by pick-and-place machines, in high volume manufacturing processes. The advantage is that it can be implemented quickly using manual placement of the optical components on the solder pads.
- The problem with solder self-alignment, however, is its alignment accuracy limitation. Many carrier-class fiber optic components require alignment accuracy of a few micrometers to sub-micrometer accuracy. Existing solder alignment processes generally cannot achieve such tolerances.
- The present invention is directed to a process for assembling micro-optical systems, such as optoelectronic and/or fiber optic components. It uses solder self-alignment to achieve a coarse, passive alignment of optical components relative to the optical bench. The fine, final alignment, however, is performed using plastic deformation of the optical components to thereby improve the alignment of the optical components. As a result, alignment accuracies of a few micrometers to sub-micrometer are attainable, if required.
- In general, according to one aspect, the invention features a process for assembling micro-optical systems. This process comprises depositing pads at locations on optical benches determined by intended engagement points between optical components and the optical benches. The optical components are then placed on these solder pads. A solder reflow process is then performed to join the optical components to the optical benches using the solder pads. During this process, self-alignment of the optical components is allowed using the solder surface tension. Finally, according to the invention, after solidification of the solder, the alignment of the optical components is improved by plastically deforming the components on the benches.
- In typical applications, the solder reflow process results in the positioning of the optical components to accuracies of between 2 and 10 micrometers. Then, the final step of improving the alignment using plastic deformation results in the alignment of the components to about 1 micrometer or better.
- In one implementation, the plastic deformation is performed in an active alignment process. Specifically, optical signals are directed to the optical component and the optical components deformed in response to the optical signals after interaction with the optical components.
- In another implementation, the step of plastically deforming the optical components comprises deforming the optical components in response to metrology data describing in the positions of the optical components relative to the benches and also so in response to the desired positions of the optical components.
- To facilitate the solder attachment process, in some embodiments, solder or metal pads are predeposited on feet of the optical components. Alternatively, or in addition, solder preforms can be further placed between the optical components and the solder pads of the benches.
- In one example, the optical components are placed on the solder pads manually. Vacuum wands are preferably used to manipulate the small optical components.
- In alternative processes, pick-and-place machines are used, such as flip chip bonders, to place the optical components on the benches.
- Further, lateral registration features are helpful in some implementations to facilitate the initial placement of the optical components on the pads. Registration features can also be further used to control the subsequent self-alignment process. These registration features are formed on the bench surface in one implementation. Alternatively, separate templates are used.
- In some implementations, magnetic fixturing is used at least after the placement of the optical components on the optical bench to hold the optical components on the optical bench. This is typically accomplished by providing optical components that include mounting structures that are made from a ferromagnetic material, such as nickel or iron. A magnetic field is oriented at least partially orthogonal to the bench in a downward direction toward the bench.
- In general, according to another aspect, the invention also features an unpopulated bench precursor structure. This structure comprises a bench. Typically, the benches are manufactured from a temperature stable substance such as silicon or beryllium nitride, or aluminum nitride. The pads are predeposited on the bench at locations determined by desired engagement points between the optical components and the optical bench. Registration features are further provided on the bench in or near the solder pads for supporting the optical components at a predetermined position vertically on the bench.
- The above and other features of the invention including various novel details of construction and combinations of parts, and other advantages, will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular method and device embodying the invention are shown by way of illustration and not as a limitation of the invention. The principles and features of this invention may be employed in various and numerous embodiments without departing from the scope of the invention.
- In the accompanying drawings, reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale; emphasis has instead been placed upon illustrating the principles of the invention. Of the drawings:
- FIG. 1 is a flow diagram illustrating one manufacturing process using solder self-alignment with optical component deformation fine alignment, according to the present invention;
- FIG. 2A is a perspective view showing an unpopulated optical bench with predeposited pads forming an unpopulated optical bench precursor structure with the optical components schematically shown ready for installation or placement on the pads of the bench, according to the present invention;
- FIG. 2B is a perspective view of a bench template according to the present invention;
- FIG. 3 is a perspective view showing the populated optical bench;
- FIG. 4 is a detailed perspective view showing the interaction between the bench spacers and optical components after solder reflow; and
- FIG. 5 shows the fine alignment process in which the optical components are plastically deformed to thereby improve the alignment of the system.
- FIG. 1 is a flow diagram illustrating an optical system manufacturing process embodying the principles of the present invention.
- Specifically, two preassembly or subassembly steps are typically performed, according to the present implementation.
- First, optical components are assembled from optical mounting structures and optical elements in
step 110 as required. This component level assembly is avoided in some implementations, however, by monolithic fabrication of the components. - Further, metal or other material is deposited on the targeted optical bench in
step 112 to form the bond pads. - In some embodiments, the bond pad is defined by a gold layer. For some optical benches, actually a multi layer structure is used, such as a titanium or chromium adhesion is layer, a nickel or platinum barrier layer, and a gold layer. This gold layer defines the bond pad.
- Solder preforms are then placed on the defined pad. Generally, PbSnAu, AuSn, InPbAg, or InPdAu solders are currently used. Alternatively, predeposited solder is used, but typically organic binder materials are included in these solders. These organics are not desirable in optoelectronic applications.
- Reactive solders that are directly deposited on the bench to form the bond pads are still another option.
- FIG. 2A illustrates the result of the subassembly step.
- In the exemplary
optical subsystem 10, the optical components are divided into two classes: 1) highprecision alignment components 25; 2) and lowprecision alignment components 35. - For the
low precision components 35, alignment is less critical. Examples include detectors d, WDM filters f, etalons e, isolators i, and fold mirrors m. - The
high precision components 25 require additional alignment beyond that available using only solder self-alignment. Examples of these components include lenses 1, fiber endfaces fe, and micro electromechanical systems (MEMS) devices such tunable filters tf. - In the illustrated example, the
high precision components 25 each comprise an opticalcomponent mounting structure 12 and anoptical element 14. In one example, the optical component mounting structures are manufactured using the LIGA process. LIGA is a German acronym that stands for lithography, plating, and molding. Currently, theoptical elements 14 include lenses, which are manufactured using an etching and/or mass transport processes in gallium phosphide or silicon, and MEMS devices. Preferably, theoptical elements 14 are solder bonded to the respective mountingstructures 12. Although in other implementations, the components are monolithically formed using, for example, deep RIE and metal deposition. - In some implementations, the mounting structures or at least their feet are coated to facilitate the solder bonding process. In one example, they are gold coated. Solder can also be predeposited onto the feet of the mounting structures.
- For the
bench preassembly step 112, solder or metal material is deposited on theoptical bench 5 to thereby form thebond pads 40 on an unpopulated optical bench precursor structure. Thesepads 40 are deposited on the bench at locations determined by the desired engagement points between theoptical components optical bench 5. - In one embodiment, spacers42 are further provided on the
bench 5, in or near thesolder pads 40 for supporting theoptical components - Referring back to FIG. 1, in the
placement step 114, the optical components are placed on the optical bench, as illustrated in FIG. 2 by the arrows. - In one embodiment, the optical components are placed manually on the solder pads using, for example, vacuum wands.
- In an alternative embodiment, the optical components are placed on the solder pads using a pick-and-place machine. Flip chip bonders are capable for the required precision placement. In one example, the
optical components 25 are tack bonded to the bond pads of the optical bench. - In one implementation, a permanent magnet or
electromagnet 60 is used to hold thecomponents bench 5 after placement. Themagnet 60 is oriented so that the magnetic field is orthogonal to the benches top surface or has a vector component in that direction. - FIG. 2B illustrates a placement jig or
template 70 that is used to facilitate the placement of the optical components on thebench 5. Specifically, thetemplate 70 is aligned over thebench 5. Thetemplate 70 has through-holes or registration features 72 into which the optical component are inserted so that they are aligned over the bond pads on thebench 5. Thejig 70 can be manufactured from graphite or silicon. - FIG. 3 illustrates the result of the
placement step 114, with theoptical bench 5 having received theoptical components - Referring back to FIG. 1, after the placement step, the bench with optical components is placed in a solder reflow oven or other reflow device. Ovens are useful because they create the optimum solder reflow environments in which the solder is raised to a liquidous temperature in an forming gas atmosphere so that the components are simultaneously bonded to the optical bench while the solder surface tension pulls the optical components into alignment relative to the solder pads. Typically, this can align the optical components on the optical benches to accuracies of 2 to 10 micrometers.
- FIG. 4 illustrates the result of the reflow process in which the various
optical components bench 5. This detailed view further illustrates the operation of thespacers 42. Specifically spacers 42 function to act is stand-offs between thebench 5 and the mountingstructures 12 so that they are fixed at a predetermined height above the bench even after solidification, i.e., shrinkage, of the solder in thebond pads 40. - Finally, in
step 118, active and/or passive fine alignment is performed by plastic deformation of the high precisionoptical components 25. - This is illustrated in FIG. 5. In the illustrated example, jaws J1, J2 of an alignment system engage the individual
optical components 25 and plastically deform the mountingstructures 12 of the optical components to improve their alignment relative to theoptical system 10. - As also illustrated by FIG. 5, this alignment can be an active alignment process where an
optical signal generator 210 is used to generate an optical signal that interacts with the optical element (lens) 14 of theoptical component 25. The alignment is then performed relative to the optical signal after interaction with the optical component. - In an alternative implementation, metrology data are collected which indicates the actual positions of the
optical components 25 on theoptical bench 5. The alignment system then plastically deforms theoptical components 25 relative to this metrology data and additional data that dictate the desired positions of the optical components relative to the optical benches and/or relative to other optical components. - While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
Claims (2)
1. An unpopulated optical bench precursor structure comprising:
a bench;
solder pads deposited on the bench at locations determined by engagement points between optical components and the optical bench; and
spacers on the bench and in or near the solder pads for supporting the optical components at a predetermined position vertically on the bench.
2. An unpopulated optical bench precursor structure as claimed in claim 1 , further comprising a template for facilitating the placement of optical components on the bench.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/391,835 US20030162003A1 (en) | 2001-03-08 | 2003-03-19 | Manufacturing system using solder self-alignment with optical component deformation fine alignment |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/802,731 US6543114B2 (en) | 2001-03-08 | 2001-03-08 | Manufacturing system using solder self-alignment with optical component deformation fine alignment |
US10/391,835 US20030162003A1 (en) | 2001-03-08 | 2003-03-19 | Manufacturing system using solder self-alignment with optical component deformation fine alignment |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US09/802,731 Division US6543114B2 (en) | 2001-03-08 | 2001-03-08 | Manufacturing system using solder self-alignment with optical component deformation fine alignment |
Publications (1)
Publication Number | Publication Date |
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US20030162003A1 true US20030162003A1 (en) | 2003-08-28 |
Family
ID=25184538
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/802,731 Expired - Lifetime US6543114B2 (en) | 2001-03-08 | 2001-03-08 | Manufacturing system using solder self-alignment with optical component deformation fine alignment |
US10/391,835 Abandoned US20030162003A1 (en) | 2001-03-08 | 2003-03-19 | Manufacturing system using solder self-alignment with optical component deformation fine alignment |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
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US09/802,731 Expired - Lifetime US6543114B2 (en) | 2001-03-08 | 2001-03-08 | Manufacturing system using solder self-alignment with optical component deformation fine alignment |
Country Status (3)
Country | Link |
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US (2) | US6543114B2 (en) |
AU (1) | AU2002236926A1 (en) |
WO (1) | WO2002073278A2 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6970628B2 (en) | 2004-04-15 | 2005-11-29 | Inplane Photonics, Inc. | Active optical alignment and attachment thereto of a semiconductor optical component with an optical element formed on a planar lightwave circuit |
Families Citing this family (8)
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US7124928B2 (en) * | 2001-01-16 | 2006-10-24 | Axsun Technologies, Inc. | Optical component installation and train alignment process utilizing metrology and plastic deformation |
US6340302B1 (en) * | 2001-02-06 | 2002-01-22 | Micron Technology, Inc. | Apparatus for establishing an electrical connection with a wafer to facilitate wafer-level burn-in and methods |
US20030196752A1 (en) * | 2002-04-17 | 2003-10-23 | Freund Joseph Michael | Epoxy tacking for optoelectronic device placement |
US7170151B2 (en) * | 2003-01-16 | 2007-01-30 | Philips Lumileds Lighting Company, Llc | Accurate alignment of an LED assembly |
US6947229B2 (en) * | 2003-12-19 | 2005-09-20 | Intel Corporation | Etalon positioning using solder balls |
US7146083B2 (en) * | 2004-03-31 | 2006-12-05 | Imra America, Inc. | Etched plate alignment method and apparatus |
WO2012148662A1 (en) * | 2011-04-29 | 2012-11-01 | Bae Systems Information And Electronic Systems Integration Inc. | Rapid optical assembly via simultaneous passive bonding |
US10209477B1 (en) * | 2017-05-25 | 2019-02-19 | Lockheed Martin Coherent Technologies, Inc. | Systems and methods for reconfigurable micro-optic assemblies |
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-
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- 2002-01-30 WO PCT/US2002/002731 patent/WO2002073278A2/en not_active Application Discontinuation
- 2002-01-30 AU AU2002236926A patent/AU2002236926A1/en not_active Abandoned
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US4878611A (en) * | 1986-05-30 | 1989-11-07 | American Telephone And Telegraph Company, At&T Bell Laboratories | Process for controlling solder joint geometry when surface mounting a leadless integrated circuit package on a substrate |
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US5257336A (en) * | 1992-08-21 | 1993-10-26 | At&T Bell Laboratories | Optical subassembly with passive optical alignment |
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US6970628B2 (en) | 2004-04-15 | 2005-11-29 | Inplane Photonics, Inc. | Active optical alignment and attachment thereto of a semiconductor optical component with an optical element formed on a planar lightwave circuit |
Also Published As
Publication number | Publication date |
---|---|
AU2002236926A1 (en) | 2002-09-24 |
US6543114B2 (en) | 2003-04-08 |
WO2002073278A2 (en) | 2002-09-19 |
US20020124375A1 (en) | 2002-09-12 |
WO2002073278A3 (en) | 2003-11-06 |
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