The post-weld shift (PWS)-induced fiber-alignment shifts of fiber-ferrule clip (FFC) joints in butterfly laser packaging by using laser-welding techniques and a high-magnification, video-probe camera system were studied experimentally and numerically. The measured results show that the fiber shifts of FFC joints with a 5-µm gap between the clip and ferrule exhibited shifts less than that without a gap. This suggests that the 5-µm gap design may be more suitable for FFC joints in laser packaging. The experimental measurements of fiber shifts in FFC joints were in reasonable agreement with the numerical calculations of the finite-element method (FEM) analysis. The major fiber-shift formation mechanisms of FFC joints in the laser-welding process may come from the mismatch of the thermal expansion coefficient, the solidification shrinkage, and the residual stresses within the FFC joint, but solidification shrinkage is the dominant cause. This study demonstrates that the FEM is an effective method for predicting PWS-induced fiber-alignment shifts in lasermodule packaging.
We present a novel image acquisition system to measure the post-weld-shift(PWS) in butterfly package for laser diode module.The results show that the measurements of PWS were l.7pm and 4.7 pm in X and Z-axis, respectively. This, indicates that the domination of PWS of the fiber in butterfly package is along z-axis.
The post-weld-shift (PWS) induced fiber alignment shifts of fiber ferrule-clip (FFC) joints in high-speed butterfly laser packaging by laser welding technique has been studied experimentally and numerically. There are two types of clip design in the FFC joint: the type I design is without a gap between clip and fiber ferrule and type I1 is a 5 pm gap. Using a novel 230x high magnification video probe camera with image acquisition system, the measured results showed that the fiber shifts of FFC joints with the type I1 exhibited shifts less than that w i t h the type I. The experimental measurements of fiber shifts were in reasonable agreement with the numerical calculations of the finite-element method (FEM) analysis. This study has demonstrated that the FEM is an effective method for predicting PWS induced fiber alignment shifts in laser module packaging.I. INTRODUCTION There are various types of laser module package designs.The coaxial and box-type are the most common styles'. The coaxial-type package designs based on TO (transistor outline)-Can are selected because fabrication costs are important and the performance requirement in lightwave transmission systems is not so high; whereas, the box-type design of the butterfly package with a fiber pigtail is widely used in higher performance devices that require high powered output, high speed, high reliability, a thermoelectric cooler, and a number of components. One of the greatest challenges in the packaging of the box-type butterfly laser modules by employing laser welding is to pursue a reliable and accurate jointing process. However, during the welding process, the rapid solidification of the welded region and the associated material shrinkage oRen cause a post-weld-shift (PWS) 2J between the welded components. For a typical single-mode fiber application, if the PWS induced fiber alignment shift by the laser welding joining process is even a few micrometers, up to 50 % or greater loss in coupled power might be incurred. The fiber alignment shift of the PWS effect in the laser welding process has a significant impact on the laser module package manufacturing yield'". Therefore, analyzing the fiber alignment shift and formulating methods to minimize fiber alignment shifts introduced by the PWS are key research subjects in laser welding techniques for optoelectronic module packaging applications.There are so many components in buttertly packages that it is difficult to identify the specific components which are responsible for the fiber alignment shift de to the PWS effect in laser welding technique. Furthermore, the order of the fiber alignment shift is quite small, in the micron range which makes it a difficult task finding the proper reference system to measure the fiber alignment shift in the butterfly packages. In this paper, we have studied the fiber alignment shifts introduced in the key component, the fiber ferrule-clip (FFC) assembly in the butterfly laser package. Anovel 23Ox high magnification video probe camera with image acquisition system was used t...
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