Hyperbolic Lens Fiber Optic Interface With Self-Aligning Ridge
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Solution Overview
Problem
Fiber optic interface modules for consumer electronics require low-cost, simple manufacturing with high data rate compatibility and forgiving misalignment tolerances, as traditional copper cables are limited in transmission distance and flexibility at high data rates.
Innovation Solution
A fiber optic interface module design featuring a hyperbolic lens shape with specific radius and back focus distance, combined with a parabolic gradient-index optical fiber core, to maintain coupling efficiency and tolerate lateral misalignment, utilizing passive alignment for cost-effective and efficient optical coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional alignment methods are used, then manufacturing precision can be achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The optical fiber pigtail is designed to self-align with the lens through geometric features (ridge structure, facet alignment) without requiring external alignment mechanisms or complex adjustment procedures. The fiber automatically positions itself at the correct location and orientation relative to the lens during insertion.
Solution Approach 2:
The lens and optical fiber pigtail are pre-positioned and pre-aligned during the molding process. The ridge structure is formed in advance on the lens, and the fiber is pre-configured with its facet orientation, so that when assembled, alignment is achieved without requiring complex post-assembly adjustments.
2Reliability
If complex alignment procedures are implemented, then coupling efficiency can be improved, but manufacturing cost and time increase
Solution Approach 1:
The system achieves high coupling efficiency through self-aligning geometric features rather than complex alignment procedures. The ridge structure and fiber facet orientation automatically ensure proper alignment when the fiber is inserted, eliminating the need for time-consuming manual or automated alignment processes.
Solution Approach 2:
Critical alignment features are built into the lens and fiber assembly during manufacturing. The ridge is molded onto the lens and the fiber facet is pre-cut at the correct angle, so that alignment is achieved by design rather than by adjustment during assembly.
3Reliability
If misalignment tolerance is reduced, then coupling efficiency increases, but manufacturing precision requirements increase
Solution Approach 1:
The lens and fiber are pre-configured with geometric features that define the alignment relationship. The ridge structure is formed on the lens and the fiber facet is pre-oriented, establishing the correct alignment geometry before assembly occurs.
Solution Approach 2:
The geometric features (ridge, facet) cause the fiber to automatically align with the lens during insertion. The physical geometry itself performs the alignment function, eliminating the need for external alignment mechanisms or high-precision positioning systems.
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 design achieves high coupling efficiency (≥85%) with improved misalignment tolerance, reducing manufacturing complexity and costs while enabling reliable high-data-rate transmission over short distances.
Implementation Method 1
a lens having a folded optical axis, the lens having a back focus distance F2 from a rear lens surface of the lens to a focus plane of the lens, wherein F2 ≥ 0
Implementation Method 2
an optical fiber having a numerical aperture NA F and a core with a gradient-index profile, the optical fiber being in optical communication with the lens over a folded optical path
Data Source
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AI summary
Fiber optic interface modules and assemblies using same are disclosed, wherein the modules and assemblies are tolerant to misalignment and have a high coupling efficiency. The module has at least one lens that defines a folded optical path through the module body. The folded optical path is formed by total internal reflection within the module body from an angled wall of the module. The lens has an aspheric front surface and a planar rear surface and is configured to have an optimum tolerance to a lateral misalignment relative to a light source while maintaining a high coupling efficiency between the light source and an optical fiber.