Expanded Beam Optical Ferrule with Glass-Polymer Segmentation
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Solution Overview
Problem
Existing expanded beam optical ferrules experience photodegradation due to high power density from optical fibers, leading to performance issues in optical connectors.
Innovation Solution
The optical ferrule is designed with distinct portions made of different materials, such as glass and polymer, where the glass portion handles the input and output surfaces, and the polymer portion is placed between the glass and the light redirecting surface, effectively managing high power density and reducing photodegradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polymer material is used for the entire optical ferrule, then manufacturing cost is reduced and ease of manufacture is improved, but photodegradation occurs under high power density light
Solution Approach 1:
The optical ferrule is divided into distinct portions: a polymer portion for the body and a glass insert portion for the light path. This segmentation allows each material to be optimized for its specific function - polymer for cost-effective manufacturing and glass for photodegradation resistance under high power density.
Solution Approach 2:
Different materials are used in different regions of the ferrule based on local requirements. The glass insert is placed specifically in the region exposed to high power density light to provide local photodegradation resistance, while the polymer body provides overall structural support and cost-effective manufacturing.
2Reliability
If glass material is used for the entire optical ferrule, then photodegradation resistance is improved, but manufacturing cost increases and device complexity increases
Solution Approach 1:
Instead of using glass for the entire ferrule, only the critical light-exposed region contains a glass insert. This reduces the amount of glass material needed and simplifies manufacturing compared to molding an entire glass ferrule, while still providing the necessary photodegradation resistance.
Solution Approach 2:
The ferrule uses a composite structure combining polymer and glass materials. The polymer body provides cost-effective manufacturing and structural support, while the glass insert provides photodegradation resistance in the critical light path region, achieving a balance between cost and reliability.
3Device complexity
If high power density light is handled by polymer material, then device simplicity is maintained, but performance degradation occurs due to photodegradation
Solution Approach 1:
The ferrule is segmented into a polymer body and a glass insert specifically positioned in the light path. This maintains overall device simplicity while placing glass only where high power density light exposure occurs, preventing photodegradation without adding unnecessary complexity.
Solution Approach 2:
The glass insert acts as an intermediary element between the polymer body and the high power density light. It mediates the interaction by providing photodegradation resistance where needed, allowing the polymer body to maintain structural simplicity while the glass protects against light-induced damage.
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 configuration enhances the handling of high power density light, reducing photodegradation and improving the performance and reliability of optical connectors.
Implementation Method 1
Existing expanded beam optical ferrules experience photodegradation due to high power density from optical fibers
Implementation Method 2
the glass portion handles the input and output surfaces, and the polymer portion is placed between the glass and the light redirecting surface, effectively managing high power density and reducing photodegradation
Data Source
AI summary
An optical ferrule includes an input surface for receiving and transmitting a central light ray from an optical fiber attached to the optical ferrule. A light redirecting side receives, along a first direction, the central light ray transmitted by the input surface and redirects the received light along a different second direction. The redirected central light ray exits the optical ferrule through an output surface of the optical ferrule. As the central light ray propagates in the optical ferrule from the input surface to the output surface, the central light ray propagates through distinct first and second portions of the optical ferrule having different respective first and second compositions.