Integrated Multicast Switch Without Fusion Splicing
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Solution Overview
Problem
The manufacturing of multicast switches for reconfigurable optical add-drop networks requires a large number of costly and labor-intensive fusion-splicing operations, leading to increased size, complexity, and reduced reliability due to the need for different technologies in splitter and optical switch components.
Innovation Solution
A fully integrated multicast switch design that connects optical splitters and switches using optical fibers without fusion splicing, employing planar lightwave circuit (PLC) chips and fiber holders with V-grooves to align fibers, reducing the need for fusion splices and integrating functions into fewer, more complex components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fusion-splicing operations are used to connect optical splitters and switches, then reliable optical connections can be achieved, but the manufacturing cost, labor intensity, and device complexity increase significantly
Solution Approach 1:
The patent introduces pre-aligned fiber optic cables with integrated connectors as an intermediary component between optical splitters and switches. These pre-assembled cables include alignment features and positioning structures that eliminate the need for complex fusion-splicing operations during final assembly, thereby reducing manufacturing complexity while maintaining connection reliability
Solution Approach 2:
The patent performs fiber alignment and connector assembly as preliminary actions before final device assembly. Optical fibers are pre-aligned and connected to splitters and switches with built-in positioning structures that ensure proper alignment is achieved automatically during assembly, eliminating the need for complex real-time alignment procedures
2Adaptability or versatility
If multiple individual optical components are used to implement multicast switch functionality, then design flexibility and adaptability are improved, but the physical size and manufacturing cost increase
Solution Approach 1:
The patent combines multiple optical components (splitters, switches, and fiber connections) into a single integrated optical assembly. The modular design allows different configurations to be achieved within the integrated structure, maintaining design flexibility while significantly reducing the overall physical size compared to separate component arrangements
Solution Approach 2:
The patent designs the integrated optical assembly with universal interfaces and standardized connection points that can accommodate different optical component configurations. This multi-functional design allows the same integrated structure to serve multiple network topologies and applications without requiring additional components, thereby reducing device size while maintaining adaptability
3Adaptability or versatility
If optical fibers are handled and connected using traditional methods, then flexible routing options are available, but fiber damage and handling issues increase
Solution Approach 1:
The patent uses pre-assembled fiber optic cables with integrated connectors and alignment features as intermediaries that protect the optical fibers during handling and installation. These pre-prepared cables reduce the need for field splicing and minimize fiber manipulation, thereby reducing fiber damage while maintaining routing flexibility through the modular connector design
Data Source
AI summary
In one embodiment, each of the output/input ports of each one of a plurality of optical splitters is connected to one of a plurality of optical switches by means of optical fibers without any fusion splicing in a majority of the optical fibers, and each of the input/output ports of each one of the switches is connected to one of the optical splitters by means of the optical fibers without any fusion splicing in a majority of the optical fibers. Each of the output/input ports of each one of the optical splitters may be directly connected to the ferrule and one of the input/output ports of one of the switches by the optical fibers. The optical splitters may be implemented in at least one planar lightwave circuit (PLC) chip. Optionally, at least one fiber holder defining a plurality of channels therein may be used to hold the optical fibers each of which is aligned with a corresponding output/input port of one of the optical splitters.