Compact Optical Mux Demux Using 3D Stacked Micro Lenses
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Solution Overview
Problem
Existing optical multiplexers and demultiplexers (Mux/DeMux) are too large to fit in small form-factor optical modules like QSFP, and they face challenges in achieving a broad operating wavelength range, enhanced optical performance, and cost-effectiveness while maintaining a compact size.
Innovation Solution
The design incorporates an array of micro lenses, filters, and a glass block bonded onto a substrate, with compensatory optical plates to correct errors, allowing for a compact, efficient, and cost-effective Mux/DeMux module that can fit within QSFP modules, utilizing a collimator, mirror, and micro lenses to manage light beams and wavelengths effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional optical multiplexers and demultiplexers are used, then optical performance and wavelength range are achieved, but the device size becomes too large to fit in QSFP modules
Solution Approach 1:
The patent transitions from planar optical component arrangements to a three-dimensional stacked configuration. Multiple optical components (collimators, filters, lenses) are arranged in vertical layers along the optical path, enabling compact integration while maintaining optical performance. This dimensional transition allows the device to fit within QSFP form factor constraints.
Solution Approach 2:
The patent implements nested integration by placing multiple optical components within each other's spatial envelopes. The collimator, filter array, and lens array are positioned such that their optical paths overlap or interpenetrate in three-dimensional space, maximizing space utilization and reducing overall device volume while preserving functional independence of each component.
2Volume of moving object
If device size is reduced to fit QSFP modules, then compactness is achieved, but manufacturing precision and error compensation become more challenging
Solution Approach 1:
The patent introduces compensatory optical elements (such as adjustable lenses or prisms) as intermediaries between the fixed optical components. These intermediaries can be tuned to correct alignment errors and focal deviations, compensating for manufacturing tolerances and assembly variations without requiring ultra-precise manufacturing of all components.
Solution Approach 2:
The patent employs adjustable optical parameters (such as lens focal length, filter position, or component spacing) that can be modified after assembly to optimize performance. This allows the system to compensate for manufacturing variations by tuning parameters rather than relying solely on precise fabrication tolerances.
3Area of stationary object
If compact design is implemented, then footprint is reduced, but device complexity and component integration difficulty increase
Solution Approach 1:
The patent divides the optical system into discrete functional modules (collimator section, filter section, lens section, detector section) that can be independently designed, manufactured, and tested. This segmentation allows complex functionality to be achieved through modular assembly, reducing integration difficulty despite the compact overall form factor.
Solution Approach 2:
The patent designs optical components that serve multiple functions within the compact architecture. For example, certain optical elements simultaneously perform collimation and focusing, or filters serve both wavelength selection and spatial positioning functions, thereby reducing the total number of components needed and simplifying integration.
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
This design achieves an 85% reduction in substrate footprint, enabling the module to fit within QSFP, while enhancing optical performance and reducing manufacturing costs, and allows for simultaneous multiplexing and demultiplexing functions with improved error compensation.
Implementation Method 1
an optical device to generate a collimated light beam
Implementation Method 2
an array of filters disposed between the mirror and the micro lenses
Implementation Method 3
an array of micro lenses
Implementation Method 4
a mirror
Data Source
AI summary
Designs of optical devices providing multiplexing or demultiplexing functions are disclosed. According to one embodiment, an optical device or an assembly employs an array of micro lenses, an array of filters and a mirror or an array of mirrors all bonded onto a substrate to provide multiplexing or demultiplexing functions. To compensate for possible errors caused by some or all of these components, one or more compensatory optical plates are provided to respectively correct these errors. Depending on implementation, the compensatory optical plates may be designed differently to correct various errors.