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Optimal laser welding assembly sequences for butterfly laser module packages.

Jeong Hwan Song¹, Peter O'Brien, Frank H Peters

¹Integrated Photonics Group, Tyndall National Institute, Lee Maltings, Cork, Ireland. jeonghwan.song@tyndall.ie

|September 23, 2009

Summary

An optimized laser welding sequence for butterfly laser packages minimizes misalignment. This approach achieves high optical coupling efficiencies (73-99%) by compensating for post-weld shift and eliminating laser hammering procedures.

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Area of Science:

Optoelectronics
Manufacturing Engineering
Materials Science

Background:

Butterfly laser packages are critical optoelectronic components.
Assembly-induced misalignment affects optical coupling efficiency.
Post-Weld Shift (PWS) is a known challenge in laser welding.

Purpose of the Study:

To determine an optimal laser welding assembly sequence for butterfly laser packages.
To minimize optical coupling efficiency losses due to misalignment.
To reduce or eliminate post-processing steps like laser hammering.

Main Methods:

Modeling of initial shift during assembly.
Experimental investigation of three distinct assembly sequences.
Analysis of vertical and horizontal misalignment compensation strategies.

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Main Results:

An optimal sequence involving initial shift, front/rear welding, gripper release, and mechanical tuning was identified.
Accurate estimation of initial vertical shift compensates for Post-Weld Shift (PWS).
Elimination of laser hammering is possible through optimized package design.

Conclusions:

The proposed laser welding assembly sequence significantly enhances optical coupling efficiency in butterfly laser packages.
Precise control over initial shifts and package design are key to achieving high performance.
The optimized process leads to efficiencies ranging from 73% to 99%.