Beam Splitter in Molded Optical Coupling Units

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing optical modules require delicate alignment and tools for accurate positioning, and their construction and operation can be complex, leading to a desire for a simpler and more robust solution for mounting and stability.

Innovation Solution

An optical module design featuring a beam steering portion with a beam splitter and reflective structures, utilizing a unitary transparent body with different refractive indices to direct light beams and facilitate alignment, allowing for robust and predictable operation with minimal external interference.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If delicate alignment tools and techniques are used for positioning optical elements, then alignment precision is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvealignment precisionVSAvoidcomplexity of mounting and alignment

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The optical module is designed with self-aligning features where the beam steering portion and optical elements automatically position themselves relative to each other through the molded structure, eliminating the need for delicate external alignment tools and techniques during assembly

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Multiple optical elements including the beam steering portion, beam splitter, and reflective structures are integrated into a single molded optical module, reducing the number of separate components that require alignment and simplifying the overall assembly process

Inventive Principle:

Principle #5Merging (Combining)

2Ease of operation

If monolithic optical modules with beam steering portions are used, then light direction control is improved, but construction complexity increases

Engineering Contradiction:

Improvelight direction controlVSAvoidconstruction complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical beam steering mechanisms with optically-controlled beam steering using reflective facets and beam splitters integrated into the molded structure, allowing light direction control through optical paths rather than mechanical movement

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The beam steering portion serves multiple functions simultaneously: it steers the light beam, splits the beam into signal and fractional components, and provides alignment references, reducing the need for separate components and simplifying construction

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If beam splitting is implemented for power monitoring, then monitoring capability is improved, but light beam path complexity increases

Engineering Contradiction:

Improvemonitoring capabilityVSAvoidbeam path complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The beam splitter acts as an intermediary element that divides the light beam into signal and fractional paths, enabling power monitoring without interfering with the main signal path, while the molded structure maintains simple overall geometry

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The optical module effectively directs light beams with high precision and stability, enabling robust assembly and reduced manufacturing costs by using total internal reflection and predictable beam splitting, allowing for precise alignment and efficient power distribution between signal and fractional light beams.

Implementation Method 1

The optical module, and in particular the beam steering portion that can include a beam splitter, can divide the initial beam into a signal light beam and a fractional light beam

Methodology Applied

Scientific EffectBeam splitting: Reflection

Implementation Method 2

utilizing a unitary transparent body with different refractive indices to direct light beams and facilitate alignment, allowing for robust and predictable operation

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Data Source

PatentUS10180580B2Beam splitting for laser power monitoring in molded optical coupling units

Publication Date: 2019.01.15 FCI USA LLC

AI summary

An optical module can include a beam steering portion and a first side defining an inner surface that faces the beam steering portion. The optical module can further include a second side that defines an inner surface adjacent to the inner surface of the first side. The inner surface of the second side can face the beam steering portion. The optical module can be configured to direct an initial light beam from the first side to the beam steering portion along a first direction. The optical module, and in particular the beam steering portion that can include a beam splitter, can divide the initial beam into a signal light beam and a fractional light beam.