Field-Configurable Optical Devices to Reduce Splitter SKUs

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Solution Overview

Problem

Optical communication networks require multiple couplers with different splitting ratios, leading to increased manufacturing, inventory, and installation complexity due to the need for numerous stock keeping units (SKUs), which adds cost and logistical challenges.

Innovation Solution

Field-configurable optical devices with a housing containing a splitter and multiple couplers of varying splitting ratios, allowing in-field configuration through fiber optic jumper assemblies to change the splitting ratio, reducing the need for multiple SKUs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple couplers with different splitting ratios are manufactured and inventoried, then the optical network can support various splitting ratio requirements, but the manufacturing complexity, inventory requirements, and installation complexity increase significantly

Engineering Contradiction:

Improvesplitting ratio configurabilityVSAvoidnumber of SKUs

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The optical device is designed with multiple couplers of different splitting ratios integrated within a single housing, allowing one universal device to replace multiple specialized couplers. The device can be configured in the field by connecting jumper assemblies to different coupler inputs, enabling a single SKU to provide multiple splitting ratio options (e.g., 90/10, 80/20, 70/30, 60/40) without requiring separate manufactured parts for each ratio.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The device transitions from a fixed splitting ratio design to a dynamically configurable design. The splitting ratio is not determined at manufacturing time but can be changed in the field by reconfiguring the jumper connections between input ports and internal couplers, allowing the optical network to adapt to different requirements without physical replacement of components.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If multiple individual coupler parts are manufactured and inventoried, then different splitting ratios are available, but the cost and logistical complexity of building optical networks increases

Engineering Contradiction:

Improvesplitting ratio optionsVSAvoidmanufacturing and inventory cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Multiple coupler components with different splitting ratios that would traditionally be manufactured and inventoried separately are merged into a single integrated optical device housing. This consolidation reduces the total number of unique parts that need to be manufactured, stored, and managed, thereby reducing manufacturing overhead and inventory carrying costs while maintaining all necessary splitting ratio options.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

A single universal optical device housing contains multiple couplers and allows configuration for various splitting ratios through jumper assembly connections, eliminating the need to manufacture and maintain separate inventory for each splitting ratio variant, thus reducing overall manufacturing and inventory costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If multiple SKUs are used to provide different splitting ratios, then the optical network requirements are met, but the installation team faces increased complexity in selecting and installing the correct parts

Engineering Contradiction:

Improvesplitting ratio coverageVSAvoidinstallation simplicity

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The optical device provides a universal solution that eliminates the need for installation teams to select from multiple different coupler models. A single device type is installed at all locations, and the desired splitting ratio is achieved by connecting jumper assemblies to appropriate internal coupler inputs, simplifying the installation process to a straightforward connection task rather than requiring model selection and differentiation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12392979B2Optical devices having internally field-configurable splitting ratios and methods of using the same

Publication Date: 2025.08.19 CORNING RES & DEV CORP

AI summary

Field-configurable optical devices and methods are disclosed. In one example, a field-configurable optical device includes a housing defining an enclosure, an input port located at the housing, a pass-through port located at the housing, a plurality of output ports located at the housing, a splitter disposed within the enclosure, a plurality of couplers within the enclosure, each coupler including an input, a first output, and a second output. Each coupler has a power splitting ratio between the first output and the second output that is different from the other couplers. An input port fiber optic jumper assembly within the enclosure. A pass-through port fiber optic jumper assembly is within the enclosure. Moving the input port fiber optic jumper assembly and the pass-through port fiber optic jumper assembly from a first coupler to a second coupler of the plurality of couplers changes the power splitting ratio of the field-configurable optical device.