High Power Fiber Optic Coupler Packaging

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Solution Overview

Problem

High-power fiber-optic couplers face thermal degradation and potential damage due to heat generation from light absorption by impurities and metal packaging, leading to inefficiencies and potential damage.

Innovation Solution

A packaging system with an internal encapsulation having a refractive index smaller than the optical fibers, surrounded by an external encapsulation with a higher refractive index, which is optically transparent and mechanically robust, to minimize light absorption and enhance thermal management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the coupler is encased in metal packaging for thermal management, then heat evacuation is improved, but light absorption and heat generation increase

Engineering Contradiction:

Improveheat evacuationVSAvoidlight absorption and heat generation

Core Design Contradiction:

TemperatureVSObject-generated harmful factors

Solution Approach 1:

The patent introduces an intermediate material (transparent encapsulation) between the light source and metal packaging. This intermediary layer allows light to pass through without being absorbed by the metal, while still enabling thermal conduction to the heat sink. The encapsulation material acts as a mediator that separates the optical function from the thermal management function.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The packaging structure is segmented into distinct functional layers: an inner transparent encapsulation layer for optical transmission, a metal heat sink layer for thermal management, and an outer protective layer. This segmentation allows each layer to perform its specific function without interfering with others, resolving the conflict between light transmission and heat dissipation.

Inventive Principle:

Principle #1Segmentation

2Loss of energy

If low refractive index encapsulation is used to minimize light losses, then coupling efficiency is improved, but thermal conductivity is reduced

Engineering Contradiction:

Improvelight lossVSAvoidthermal conductivity

Core Design Contradiction:

Loss of energyVSTemperature

Solution Approach 1:

The encapsulation system is segmented into multiple layers with different material properties. The inner layer uses low refractive index material for optimal optical coupling, while outer layers provide thermal management pathways. This segmentation allows simultaneous optimization of both optical efficiency and thermal conductivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The packaging employs composite material construction combining transparent encapsulation materials with thermally conductive metal components. The composite structure integrates materials with complementary properties: optical transparency for light transmission and thermal conductivity for heat evacuation, resolving the trade-off between these two requirements.

Inventive Principle:

Principle #40Composite materials

3Strength

If opaque metal packaging is used for structural protection, then mechanical robustness is improved, but light absorption increases causing thermal degradation

Engineering Contradiction:

Improvemechanical robustnessVSAvoidlight absorption

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The packaging is segmented into an inner transparent layer that contacts the coupler and an outer metal layer for structural protection. This segmentation ensures that the metal layer does not directly absorb light, while still providing mechanical strength and protection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A transparent encapsulation layer serves as an intermediary between the light path and the opaque metal packaging. This intermediary prevents direct interaction between light and metal, eliminating light absorption by the metal while preserving its structural and protective functions.

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

This configuration reduces thermal effects and protects the coupler from impurities and moisture, maintaining high coupling efficiency and mechanical robustness while preventing light-induced heat generation.

Implementation Method 1

encapsulating the fiber-optic coupler with an internal encapsulation having a refractive index smaller than that of the coupled optical fibers

Methodology Applied

Scientific EffectRefraction: Refraction

Implementation Method 2

the low refractive index encapsulation is optically transparent for light of the range of wavelengths of the coupled fibers

Methodology Applied

Scientific EffectOptical transparency:

Implementation Method 3

surrounding the internal encapsulation with an external encapsulation having a refractive index greater than that of the internal encapsulation

Methodology Applied

Scientific EffectRefraction: Refraction

Data Source

PatentEP2230541B1Method and system for packaging a high power fibre optic coupler

Publication Date: 2016.08.31 V GEN

Figure 1A~1B
Figure 2~3

AI summary

A fiber-optic coupler packaging including an internal encapsulation for encapsulating a fiber-optic coupler, the refraction index of the internal encapsulation is smaller than the refraction index of the fiber-optic coupler, and an external encapsulation, for encapsulating the internal encapsulation, the refraction index of the external encapsulation is greater than the refraction index of the internal encapsulation, the internal encapsulation and the external encapsulation are substantially transparent to the range of wavelengths of the light traveling inside the fiber-optic coupler.