Fiber Optic Module with TIR Lens and Tray Alignment
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Solution Overview
Problem
Existing fiber optic modules for consumer electronics face challenges in simplifying the alignment of optical fibers, particularly at high data rates, due to limitations in traditional copper cables and the need for low-cost, low-power solutions that can accommodate high data transmission over short distances.
Innovation Solution
A two-piece fiber optic module design featuring a fiber tray and a body with a total-internal-reflection surface, where the fiber tray is secured to the body using adhesive, allowing for passive or active alignment of optical fibers with lenses, and includes features for tilting and adhesive receiving structures to facilitate secure and efficient optical communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional alignment methods are used for optical fibers, then alignment precision can be achieved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The device is divided into separate functional components: a fiber tray for holding and pre-positioning multiple optical fibers, and a separate body containing the optical components. This segmentation allows independent optimization of each component and simplifies the overall assembly process while maintaining alignment precision.
Solution Approach 2:
The fiber tray acts as an intermediary component between the optical fibers and the body. It provides a stable platform with built-in alignment features that facilitate precise positioning of fibers relative to the optical components in the body, reducing the complexity of direct alignment.
2Manufacturing precision
If complex alignment structures are used to secure optical fibers, then alignment precision improves, but ease of manufacture deteriorates
Solution Approach 1:
The fiber tray is designed with pre-formed alignment features and positioning structures that are created during the tray's manufacturing process. This preliminary action eliminates the need for complex alignment operations during final assembly, as the tray already contains the necessary geometric features to guide fiber positioning.
Solution Approach 2:
The alignment features are designed to be self-aligning through geometric constraints and tolerances built into the fiber tray and body interfaces. The structure enables automatic alignment during assembly without requiring additional alignment tools or complex adjustment procedures.
3Ease of manufacture
If adhesive is used to secure the fiber tray to the body, then assembly simplicity improves, but manufacturing precision requirements increase
Solution Approach 1:
The interface between the fiber tray and body incorporates localized alignment features at specific critical positions. These features concentrate the precision requirements to discrete locations rather than requiring uniform precision across the entire interface, allowing adhesive bonding to succeed with relaxed overall tolerances.
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 simplifies the alignment and securement of optical fibers, reduces fabrication costs, and enhances the efficiency of optical signal transmission by allowing for precise alignment and secure attachment of optical fibers within the module, thereby addressing the limitations of traditional copper cables and enabling high data rate transmission.
Implementation Method 1
a body (110) having a total-internal-reflection (TIR) surface for reflecting optical signals between a fiber-end datum surface (114) and active optical components
Data Source
Figure 1
Figure 2~3
Figure 4A
AI summary
Fiber trays and fiber optic modules and assemblies using the same are disclosed, wherein optical fibers (10) are secured to a fiber tray (120) that is then secured to a body (110) of the fiber module. The body defines a plurality of lenses (164, 165) that reflect light using a total-internal- reflection surface (113) to direct light to active optical components (140). The fiber tray is secured to the body such that the plurality of optical fibers may be secured within fiber support features (112) of the body that align ends of the optical fibers to the lenses defined by the body. Optical-electrical connectors employing such two-piece fiber optic modules are also disclosed, as well as methods of processing a plurality of optical fibers using a fiber tray.