Fiber Optic Module With Tray And Lens Alignment
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Solution Overview
Problem
Traditional copper cables have limitations in transmission distance and flexibility at high data rates, necessitating the use of optical fibers for consumer electronics, but existing fiber optic modules and connectors require complex and costly alignment processes.
Innovation Solution
A two-piece fiber optic module comprising a fiber tray and a body with adhesive features for securing and aligning optical fibers, allowing for passive or active alignment with lenses, simplifying the manufacturing process and reducing fabrication costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional alignment processes are used for fiber optic modules, then precise optical alignment is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The fiber tray is pre-positioned within the connector body at a location that automatically aligns fiber ends with the lens array when the connector is assembled. This preliminary positioning eliminates the need for complex post-assembly alignment procedures, resolving the contradiction between achieving precise optical alignment and reducing manufacturing complexity
Solution Approach 2:
The fiber tray acts as an intermediary component that mechanically couples the optical fibers to the lens array. By providing a stable, pre-positioned mounting structure, the fiber tray mediates the alignment relationship between fibers and lenses, simplifying the overall alignment process while maintaining precision
2Manufacturing precision
If traditional alignment processes are used for fiber optic modules, then precise optical alignment is achieved, but fabrication time and cost increase
Solution Approach 1:
The fiber tray is pre-positioned within the connector body during manufacturing, establishing the optical alignment geometry before final assembly. This preliminary action allows for simpler, faster assembly procedures while maintaining precise alignment, thereby improving fabrication efficiency without sacrificing alignment quality
Solution Approach 2:
The connector is divided into distinct components (body, fiber tray, lens array) that can be manufactured and positioned separately, then assembled in a simplified sequence. The fiber tray serves as an intermediate segment that pre-establishes alignment relationships, enabling faster overall fabrication while maintaining precision
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 solution enables efficient and cost-effective alignment of optical fibers with lenses, reducing fabrication time and costs while ensuring precise optical communication, suitable for high-data-rate applications in consumer electronics.
Implementation Method 1
secured to the body at the fiber support features with an adhesive such as an index-matching adhesive
Data Source
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AI summary
Fiber optic modules (100), fiber optic connectors (12), and methods are disclosed. In one embodiment, a fiber optic module (100) includes a body (110) and a fiber tray (120). The body includes a fiber tray recess (118) extending from a first surface, a fiber-end datum surface (114) positioned at an end of the fiber tray recess, and a plurality of lens surfaces (130). The plurality of lens surfaces, the fiber-end datum surface, and intervening portions of the body define a plurality of lenses each having a linear optical axis. The fiber tray includes a plurality of fiber support features (122) disposed on a first surface. The plurality of fiber support features is configured to receive a plurality of optical fibers. The fiber tray is disposed within the fiber tray recess and secured to the body.