OPTICAL MODULE

Abstract

An optical module includes: a stem including a first surface and a second surface opposite to the first surface; a thermoelectric cooler including a heat-releasing substrate fixed to the first surface; a semiconductor laser element attached to the thermoelectric cooler; a cap fixed to the first surface and covering the thermoelectric cooler and the semiconductor laser element; a lens fixed to the cap; and a restriction body fixed to the second surface. The linear thermal expansion coefficients of the heat-releasing substrate and the restriction body are smaller than the linear thermal expansion coefficient of the stem.

Claims

1. An optical module comprising: a stem including a first surface and a second surface opposite to the first surface; a thermoelectric cooler including a heat-releasing substrate fixed to the first surface; a semiconductor laser element attached to the thermoelectric cooler; a cap fixed to the first surface and covering the thermoelectric cooler and the semiconductor laser element; a lens fixed to the cap; and a restriction body fixed to the second surface, wherein the linear thermal expansion coefficients of the heat-releasing substrate and the restriction body are smaller than the linear thermal expansion coefficient of the stem.

2. The optical module according to claim 1, wherein the linear thermal expansion coefficient of the restriction body is smaller than the linear thermal expansion coefficient of the heat-releasing substrate.

3. The optical module according to claim 1, wherein the linear thermal expansion coefficient of the restriction body is larger than the linear thermal expansion coefficient of the heat-releasing substrate.

4. The optical module according to claim 1, wherein a recess is formed at the second surface and the restriction body is provided in the recess.

5. The optical module according to claim 4, comprising: a lead pin penetrating around the recess through the stem; and a flexible substrate fixed to the second surface and electrically connected with the lead pin.

6. The optical module according to claim 1, comprising a lead pin penetrating through the stem, wherein a through-hole through which the lead pin penetrates is formed at the restriction body.

7. The optical module according to claim 6, wherein the contact area of the restriction body and the second surface is larger than the contact area of the heat-releasing substrate and the first surface.

8. An optical module comprising: a stem including a first surface, a second surface opposite to the first surface, and a side surface; a thermoelectric cooler including a heat-releasing substrate fixed to the first surface; a semiconductor laser element attached to the thermoelectric cooler; a cap fixed to the first surface and covering the thermoelectric cooler and the semiconductor laser element; a lens fixed to the cap; and a restriction body fixed to the side surface at a position closer to the second surface than the first surface, wherein the linear thermal expansion coefficients of the heat-releasing substrate and the restriction body are smaller than the linear thermal expansion coefficient of the stem.

9. The optical module according to claim 8, wherein the restriction body is fixed to the side surface on the second surface side of a middle position at which the distance from the first surface is equal to the distance from the second surface.

10. The optical module according to claim 8, wherein the restriction body is annular in plan view.

11. The optical module according to claim 8, wherein the restriction body is semicircular.

12. The optical module according to claim 1, further comprising an optical fiber provided outside the cap and facing the lens, wherein the optical fiber is provided at a position where a coupling efficiency peak is obtained at a temperature lower than the central temperature of an operation temperature.

13. The optical module according to claim 1, wherein the stem is made of SPCC, the heat-releasing substrate is made of aluminum nitride or alumina, and the restriction body is made of aluminum nitride, alumina, kovar, or inver.

14. The optical module according to claim 2, wherein a recess is formed at the second surface and the restriction body is provided in the recess.

15. The optical module according to claim 3, wherein a recess is formed at the second surface and the restriction body is provided in the recess.

16. The optical module according to claim 2, comprising a lead pin penetrating through the stem, wherein a through-hole through which the lead pin penetrates is formed at the restriction body.

17. The optical module according to claim 3, comprising a lead pin penetrating through the stem, wherein a through-hole through which the lead pin penetrates is formed at the restriction body.

18. The optical module according to claim 4, comprising a lead pin penetrating through the stem, wherein a through-hole through which the lead pin penetrates is formed at the restriction body.

19. The optical module according to claim 5, comprising a lead pin penetrating through the stem, wherein a through-hole through which the lead pin penetrates is formed at the restriction body.

20. The optical module according to claim 9, wherein the restriction body is annular in plan view.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 is a cross-sectional view of an optical module according to Embodiment 1.

[0015] FIG. 2 is a cross-sectional view illustrating the optical module at high temperature.

[0016] FIG. 3 is a cross-sectional view illustrating the optical module at low temperature.

[0017] FIG. 4 is a cross-sectional view of an optical module according to Embodiment 2.

[0018] FIG. 5 is a bottom view of the stem and another portion.

[0019] FIG. 6 is a cross-sectional view of an optical module according to Embodiment 3.

[0020] FIG. 7 is a plan view of a restriction body and another portion according to Embodiment 4.

[0021] FIG. 8 is a cross-sectional view of an optical module according to Embodiment 4.

[0022] FIG. 9 is a cross-sectional view illustrating the optical module at high temperature.

[0023] FIG. 10 is a diagram illustrating a restriction body and other components according to Embodiment 5.

[0024] FIG. 11 is a cross-sectional view of an optical module according to Embodiment 6.

[0025] FIG. 12 is a diagram illustrating the relation between the package ambient temperature and the coupling efficiency.

[0026] FIG. 13 is a cross-sectional view illustrating the optical module at low temperature.

DESCRIPTION OF EMBODIMENTS

[0027] The following describes an optical module according to an embodiment of the present invention with reference to the accompanying drawings. Identical or corresponding components are denoted by an identical reference sign or an identical name, and duplicate description thereof will be omitted in some cases.

Embodiment 1

[0028] FIG. 1 is a cross-sectional view of an optical module 10 according to Embodiment 1. The optical module 10 includes a stem 13 including a first surface 13a and a second surface 13b opposite to the first surface 13a. A thermoelectric cooler 16 is provided to the first surface 13a of the stem 13. The thermoelectric cooler 16 is a thermoelectric cooler (TEC) in which a heat-absorbing substrate 16b and a heat-releasing substrate 16c are attached on the respective sides of a Peltier element 16a. The heat-releasing substrate 16c is fixed to the first surface 13a. The fixation method is not particularly limited but is, for example, soldering by using AuSn, SnAgCu, or the like. Alternatively, the fixation method may be welding.

[0029] A semiconductor laser element 18 is attached to the thermoelectric cooler 16 through a heat-releasing block or the like. Specifically, the semiconductor laser element 18 is attached to the heat-absorbing substrate 16b through a heat-releasing block or the like. The semiconductor laser element 18 is, for example, a laser diode. The temperature of the semiconductor laser element 18 is adjusted by the thermoelectric cooler 16.

[0030] A cap 20 is fixed to the first surface 13a. The cap 20 covers the thermoelectric cooler 16 and the semiconductor laser element 18. A lens 22 is fixed to the cap 20. The lens 22 condenses light emitted from the semiconductor laser element 18. The semiconductor laser element 18 can be sealed in an airtight manner by fixing the cap 20 holding the lens 22 to the first surface 13a of the stem 13 by, for example, resistance welding.

[0031] A restriction body 30 is fixed to the second surface 13b. The fixation method is not particularly limited but is, for example, soldering by using AuSn, SnAgCu, or the like. Alternatively, the fixation method may be welding. The restriction body 30 is, for example, a metal having a plate shape. The linear thermal expansion coefficients of the restriction body 30 and the heat-releasing substrate 16c are smaller than the linear thermal expansion coefficient of the stem 13. The restriction body 30, the heat-releasing substrate 16c, and the stem 13 may be each made of any material that satisfies this relation among the linear thermal expansion coefficients. The linear thermal expansion coefficient of the restriction body 30 is preferably smaller than the linear thermal expansion coefficient of the heat-releasing substrate 16c.

[0032] A power supply lead pin penetrating through the stem 13 is provided to supply electrical power to the semiconductor laser element 18 and the thermoelectric cooler 16. An optical signal output from the semiconductor laser element 18 is maintained at high quality so that the temperature of the semiconductor laser element 18 is adjusted to be constant by the thermoelectric cooler 16.

[0033] FIG. 2 is a diagram illustrating the status of thermal deformation of the optical module 10 at high temperature. FIG. 3 is a diagram illustrating the status of thermal deformation of the optical module 10 at low temperature. FIGS. 2 and 3 relate to the optical module in which the linear thermal expansion coefficient of the heat-releasing substrate 16c is small than the linear thermal expansion coefficient of the stem 13 and the linear expansion coefficient of the restriction body 30 is smaller than the linear thermal expansion coefficient of the heat-releasing substrate 16c. FIGS. 2 and 3 illustrate an optical fiber 32 coupled with a laser beam from the semiconductor laser element 18.

[0034] As illustrated in FIG. 2, thermal expansion of the stem 13 is restricted by both the restriction body 30 and the heat-releasing substrate 16c, but the restriction body 30 exerts larger force of restricting thermal expansion than the heat-releasing substrate 16c. Thus, thermal expansion of the second surface 13b is smaller than thermal expansion of the first surface 13a, and the stem 13 warps in a convex manner projecting toward the cap 20 side. Accordingly, the position of the semiconductor laser element 18 varies in the direction toward the optical fiber 32. In addition, the position of the lens 22 varies in the direction toward the optical fiber 32 due to thermal expansion of the cap 20, and thus variation of the distance between the semiconductor laser element 18 and the lens 22 due to thermal deformation can be reduced.

[0035] The following describes FIG. 3 illustrating thermal deformation of the optical module 10 at low temperature. The restriction body 30 exerts larger force to restrict heat contraction of the stem 13 than the heat-releasing substrate 16c, and thus the stem 13 warps in a convex manner projecting toward the restriction body 30 side. Accordingly, the position of the semiconductor laser element 18 varies in the direction toward the stem 13. In addition, the position of the lens 22 varies in the direction toward the stem 13 due to heat contraction of the cap 20, and thus variation of the distance between the semiconductor laser element 18 and the lens 22 due to thermal deformation can be reduced.

[0036] In the optical module 10 according to Embodiment 1, the heat-releasing substrate 16c is attached to the first surface 13a of the stem 13 and the restriction body 30 is attached to the second surface 13b, thereby reducing variation of the distance between the semiconductor laser element 18 and the lens 22 due to thermal deformation. Accordingly, variation of the position of the light condensation point can be reduced, and thus tracking error can be reduced.

[0037] The optical module 10 according to Embodiment 1 can be modified in various manners within characteristics thereof. The linear thermal expansion coefficients of the restriction body 30 and the heat-releasing substrate 16c need to be smaller than the linear thermal expansion coefficient of the stem 13. However, the linear thermal expansion coefficients of the restriction body 30 and the heat-releasing substrate 16c may be equal to each other. Alternatively, the linear thermal expansion coefficient of the restriction body 30 may be larger than the linear thermal expansion coefficient of the heat-releasing substrate 16c. In these cases as well, tracking error can be reduced as compared to a configuration in which the restriction body 30 is not provided.

[0038] The stem 13 may be made of, for example, cold milling steel such as SPCC. The heat-releasing substrate 16c may be made of, for example, aluminum nitride, in other words, AlN, or alumina. The restriction body 30 may be made of, for example, aluminum nitride, alumina, kovar, or inver. With these materials, the linear thermal expansion coefficient of the restriction body 30 is equal to or smaller than the linear thermal expansion coefficient of the heat-releasing substrate 16c, and the linear thermal expansion coefficient of the stem 13 is larger than the linear thermal expansion coefficients of the restriction body 30 and the heat-releasing substrate 16c. When the restriction body 30 is made of AlN or alumina, thermal conductivity of the restriction body 30 is higher than thermal conductivity of the stem 13, thereby preventing degradation of the heat-releasing characteristic of a product due to attachment of the restriction body 30. These materials are exemplary.

[0039] Optical modules according to embodiments below are similar to that of Embodiment 1, and thus the following mainly describes difference thereof from that of Embodiment 1.

Embodiment 2

[0040] FIG. 4 is a cross-sectional view of an optical module according to Embodiment 2. A recess 13c is formed at the second surface 13b. The restriction, body 30 is provided in the recess 13c. The restriction body 30 is fixed to the recess 13c by, for example, welding. The restriction body 30, which is housed in the recess 13c, is positioned between the first surface 13a and the second surface 13b.

[0041] A flexible substrate 40 is fixed to the second surface 13b of the stem 13. The flexible substrate 40 includes a high-frequency line and transmits an input electric signal to the semiconductor laser element 18 and the thermoelectric cooler 16. The stem 13 has a side surface in contact with an optical transceiver housing 42. Accordingly, heat generated through the operation of the thermoelectric cooler 16 is released to the optical transceiver housing 42.

[0042] FIG. 5 is a bottom view of the stem 13 of the optical module according to Embodiment 2. The recess 13c described above is formed at the center of the stem 13. A lead pin 44 used for power supply to the semiconductor laser element 18 and the thermoelectric cooler 16 is fixed to the stem 13. The lead pin 44 penetrates around the recess 13c through the stem 13. Accordingly, the lead pin 44 is provided at a position different from that of the recess 13c. The area and thickness of the restriction body 30 are desirably larger than those of the heat-releasing substrate 16c. The size of the recess 13c is determined to house the restriction body 30 having such area and thickness.

[0043] The flexible substrate 40 is electrically connected with the lead pin 44 to transmit an input electric signal to the semiconductor laser element 18 and the thermoelectric cooler 16.

[0044] When a flexible substrate is provided in the optical module illustrated in FIG. 1, the flexible substrate needs to be provided at the lower surface of the restriction body 30, and accordingly, the distance between the flexible substrate and the stem 13 increases as compared to a case in which the flexible substrate is directly fixed to the second surface 13b. As a result, the configuration in FIG. 1 needs to be newly designed.

[0045] However, in the optical module illustrated in FIG. 4, since the restriction body 30 is provided in the recess 13c of the stem 13, the gap between the flexible substrate 40 and the stem 13 can be made equivalent to that in a conventional product including no restriction body 30. Thus, a high-frequency line from the stem 13 to the flexible substrate 40 can be designed with an impedance equivalent to that of the conventional product, thereby avoiding degradation of the high-frequency characteristic. In addition, similarly to the conventional product, the side surface of the stem 13 can be provided in contact with the optical transceiver housing 42 to allow heat-releasing to the housing 42 by a method similar to that of the conventional product. As a result, the heat-releasing characteristic is not degraded by providing the restriction body 30 and the flexible substrate 40.

[0046] Similarly to the restriction body 30, the heat-releasing substrate 16c is attached to the stem 13 at a part where the lead pin 44 is not provided. Accordingly, the area of the restriction body 30 can be designed to be equivalent to the area of the heat-releasing substrate 16c. The thickness of the stem 13 is, for example, 1.2 mm to 1.3 mm approximately, and the thickness of the heat-releasing substrate 16c is, for example, 0.2 mm approximately. In this case, the thickness of the restriction body 30 provided in the recess 13c can be easily designed to be equivalent to or larger than the thickness of the heat-releasing substrate 16c. In this example, the depth of the recess 13c is 0.2 mm or larger, and the restriction body 30 having a thickness of 0.2 mm or larger is provided in the recess 13c.

[0047] As described above, the area and thickness of the restriction body 30 can be made equivalent to or larger than the area and thickness of the heat-releasing substrate 16c. When the linear thermal expansion coefficient of the restriction body 30 is same as the linear thermal expansion coefficient of the heat-releasing substrate 16c, the warping of the stem is reduced at least as compared to a case in which no restriction body is provided. In addition, when the linear thermal expansion coefficient of the restriction body 30 is smaller than the linear thermal expansion coefficient of the heat-releasing substrate 16c, the directions of variation of the semiconductor laser element 18 and the position of the lens 22 due to thermal deformation can be same as described in Embodiment 1.

[0048] In this manner, in the optical module according to Embodiment 2, since the recess 13c is provided to the stem 13 and the restriction body 30 is embedded in the recess 13c, tracking error can be reduced while the high-frequency characteristic and the heat-releasing characteristic equivalent to those of the conventional product are maintained.

Embodiment 3

[0049] FIG. 6 is a cross-sectional view of an optical module according to Embodiment 3. This optical module includes the lead pin 44 penetrating through the stem 13. In addition, a through-hole 30a through which the lead pin 44 penetrates is formed at the restriction body 30. Accordingly, the area of the restriction body 30 can be increased to increase the contact area of the restriction body 30 and the stem 13. For example, the contact area of the restriction body 30 and the second surface 13b can be larger than the contact area of the heat-releasing substrate 16c and the first surface 13a. When the contact areas of the restriction body 30 and the stem 13 are large, force exerted by the restriction body 30 to restrict thermal deformation of the stem 13 is increased. Accordingly, warping larger than that of the stem according to Embodiment 1 or 2 occurs to the stem 13 of the optical module according to Embodiment 3 at high temperature or low temperature, and the amount of change of the position of the semiconductor laser element 18 due to thermal change is increased.

[0050] For example, when the stem 13 is made of cold milling steel and the cap 20 is made of stainless steel, the difference between the linear thermal expansion coefficients of both members is reduced to 12 ppm approximately. In addition, when the length of the cap 20 in the optical axis direction is, for example, 5 mm to 6 mm and the length of the stem 13 in the optical axis direction is 1.2 mm to 1.3 mm, the length of the cap 20 in the optical axis direction is longer than the length of the stem 13 in the optical axis direction, and thus the amount of thermal expansion of the cap 20 is larger than the amount of thermal expansion of the stem 13. In this case, the amount of change of the position of the lens 22 due to thermal deformation is larger than the amount of change of the position of the semiconductor laser element 18 under the same condition.

[0051] As described above, when the restriction body 30 is attached to the stem 13, the positional variation directions of the semiconductor laser element 18 and the position of the lens 22 can be same. However, the amount of position change is larger at the lens 22 than the semiconductor laser element 18. In Embodiment 3, the amount of change of the position of the semiconductor laser element 18 can be increased by increasing the area of the restriction body 30, thereby reducing the amount of change of the relative positions of the semiconductor laser element 18 and the lens 22. As a result, tracking error can be further reduced.

Embodiment 4

[0052] FIG. 7 is a plan view of the stem and other components of an optical module according to Embodiment 4. A restriction body 50 is fixed to a side surface 13d of the stem 13. The restriction body 50 is annular in plan view. FIG. 8 is a cross-sectional view of the optical module according to Embodiment 4. The dashed and single-dotted line represents the center line of the stem 13. The center line is positioned between the first surface 13a and the second surface 13b. The restriction body 50 is fixed to the side surface 13d at a position closer to the second surface 13b than the first surface 13a. In other words, the restriction body 50 is attached to cover a lead-pin output side of the side surface 13d of the stem 13 but is not attached on the thermoelectric cooler 16 side. Accordingly, the restriction body 50 is provided on the second surface 13b side of the dashed and single-dotted line. The linear thermal expansion coefficients of the heat-releasing substrate 16c and the restriction body 50 are smaller than the linear thermal expansion coefficient of the stem 13.

[0053] At high temperature or low temperature, the restriction body 50 restricts thermal expansion and contraction of the lead-pin output side of the stem 13, thereby making it possible to generate warping of the stem 13 in a direction same as that in Embodiment 1. Thus, tracking error is reduced. FIG. 9 is a cross-sectional view of the optical module according to Embodiment 4 at high temperature. As illustrated in FIG. 9, the stem 13 largely expands on the first surface 13a side, but the expansion on the second surface 13b side is restricted by the restriction body 50. In this manner, in addition to the tracking-error reduction effect, the optical module according to Embodiment 4 needs no special fabrication such as formation of a recess at the stem 13, thereby avoiding increase in the cost of the stem 13.

[0054] The restriction body 50 in FIG. 8 can be modified in various manners as long as the restriction body 50 is fixed to the side surface 13d on the second surface side of a middle position at which the distance from the first surface 13a is equal to the distance from the second surface 13b. For example, the contact area of the restriction body and the stem may be smaller than that in the case of FIG. 8.

Embodiment 5

[0055] FIG. 10 is a diagram illustrating a restriction body and other components according to Embodiment 5. A restriction body 52 is semicircular and provided to the side surface 13d of the stem 13. As described in Embodiment 4, the restriction body 52 is fixed to the side surface 13d at a position closer to the second surface 13b than the first surface 13a. As illustrated in FIG. 10, the restriction body 52 does not cover the entire side surface of the stem 13 in plan view but covers part of the side surface 13d of the stem 13 in plan view. Part of the side surface 13d not covered by the restriction body 52 thermally contacts the optical transceiver housing 42. Accordingly, favorable heat-releasing from the optical module to the housing 42 is achieved while the restriction body 52 is attached.

Embodiment 6

[0056] FIG. 11 is a cross-sectional view of an optical module according to Embodiment 6. An operation temperature range is determined for an optical module as a product. For example, a product configured to operate at −5° C. to 80° C. has a central temperature of 37.5° C. A product configured to operate at −40° C. to 95° C. has a central temperature of 27.5° C. For example, the central temperature of the operation temperature range of a product is adjusted to room temperature as ambient temperature of the product.

[0057] FIG. 11 illustrates the optical fiber 32 provided outside the cap 20 and facing the lens 22. Typically, an optical fiber is provided so that a coupling efficiency peak is obtained at the central temperature of the operation temperature range. However, the optical fiber 32 according to Embodiment 6 is provided at a position where the coupling efficiency peak is obtained at a temperature lower than the central temperature of the operation temperature. Specifically, the optical fiber 32 is defocused in the direction departing from the optical module and fixed.

[0058] FIG. 12 is a diagram illustrating the relation between the package ambient temperature and the coupling efficiency. T1 and T2 represent the lowest and highest temperatures of an assumed operation temperature range. Tc represents the central temperature of the operation temperature range. Tc is, for example, room temperature at 25° C. approximately. In a “without defocus” case illustrated with the solid line, the optical fiber is provided so that the coupling efficiency peak can be obtained at the central operation temperature Tc.

[0059] For example, when the strength of bonding between the stem 13 and the restriction body 30 is weak, force exerted by the restriction body 50 to restrict thermal deformation of the stem 13 decreases along with thermal contraction of the stem 13 at low temperature. As a result, at low temperature, the tracking-error reduction effect is small and change of the coupling efficiency due to change of the ambient temperature is large. Accordingly, decrease of the coupling efficiency is large at low temperature. As a result, in a “without defocus” case illustrated in FIG. 12, high coupling efficiency is obtained at the central temperature Tc, but the coupling efficiency abruptly decreases as temperature becomes lower than Tc.

[0060] A “with defocus” case illustrated with the dashed line in FIG. 12 corresponds to the relation between temperature and the coupling efficiency when the optical fiber 32 is defocused in the direction departing from the lens 22 and fixed. In the “with defocus” case, the optical fiber 32 is provided at a position where the coupling efficiency peak is obtained at a temperature lower than the central temperature Tc of the operation temperature. FIG. 13 is a cross-sectional view of the optical module when the ambient temperature is lower than Tc in the “with defocus” case. In this case, the cap 20 thermally contracts, and accordingly, the position of the lens 22 varies in the direction toward the stem 13. Along this, the position of the condensation point of light emitted from the semiconductor laser element 18 varies in the direction toward the optical fiber 32. Since the optical fiber 32 is defocused, the coupling efficiency increases at low temperature. As a result, the coupling efficiency peak is obtained at a temperature lower than Tc.

[0061] In the optical module according to Embodiment 6, the coupling efficiency peak is shifted to the low temperature side with taken into consideration the abrupt decrease of the coupling efficiency at low temperature, for example, when the strength of bonding between the stem 13 and the restriction body 30 is weak. Accordingly, coupling efficiency change that occurs in the entire operation temperature range can be reduced. In other words, tracking error can be reduced.

[0062] The coupling efficiency abruptly decreases at low temperature not only when the strength of bonding between the stem 13 and the restriction body 30 is weak but also, for example, when force that restricts thermal deformation of the stem is weak due to characteristics of the material of the restriction body. Thus, it is effective to adjust the position of the optical fiber in the optical axis direction as described above.

[0063] Features of the optical module according to each embodiment described above may be combined as appropriate to enhance the effect of the present invention.

DESCRIPTION OF SYMBOLS

[0064] 10 optical module, 13 stem, 16 thermoelectric cooler, 18 semiconductor laser element, 20 cap, 22 lens