Integrally Molded Optical Coupler for Alignment and S/N Ratio

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Solution Overview

Problem

Conventional optical couplers face challenges in maintaining positioning accuracy and coupling efficiency due to separate components, which can lead to decreased signal-to-noise (S/N) ratios from ambient light interference.

Innovation Solution

An optical coupler with an integrally molded body containing glass and fillers, featuring an optical fiber fixing portion, a reflective portion, and a holding portion with specific side wall configurations that maintain component alignment and reduce thermal expansion effects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If separate components (microlens, optical path changing portion, V-shaped groove array) are used and fixed by a fixing unit, then the device can be assembled from individual parts, but maintaining positioning accuracy becomes difficult and coupling efficiency decreases

Engineering Contradiction:
Improvepositioning accuracyVSAvoidcomponent structure
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent integrates the microlens array, optical path changing portion, and V-shaped groove array into a single integrally molded resin body. This merging eliminates the need for separate fixing units and multiple assembly steps, thereby maintaining positioning accuracy while reducing device complexity. The integral structure ensures that all optical components are precisely positioned relative to each other without requiring additional fixation mechanisms.

Inventive Principle:
Principle #5Merging (Combining)

2Reliability

If multiple separate components are fixed together, then the device can be constructed from modular parts, but the S/N ratio decreases due to ambient light interference

Engineering Contradiction:
ImproveS/N ratioVSAvoidcomponent structure
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

By integrating all optical components into a single molded body, the patent creates a sealed optical path that prevents ambient light from entering and interfering with the optical signals. This integral structure improves the S/N ratio by eliminating gaps and interfaces where ambient light could infiltrate, while simultaneously reducing the complexity of assembling and sealing multiple separate components.

Inventive Principle:
Principle #5Merging (Combining)

3Manufacturing precision

If separate components are used with a fixing unit, then assembly is possible, but coupling efficiency between optical components decreases

Engineering Contradiction:
Improvecoupling efficiencyVSAvoidassembly process
Core Design Contradiction:
Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent achieves high coupling efficiency by integrating all optical components into a single molded structure, ensuring precise alignment between the microlens array, optical path changing portion, and V-shaped groove array. This integral manufacturing approach eliminates alignment errors that would occur with separate components and fixing units, while the molding process itself provides an efficient, automated manufacturing method that reduces assembly complexity.

Inventive Principle:
Principle #5Merging (Combining)

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 configuration enhances coupling efficiency and reduces S/N ratio degradation by maintaining precise component positioning and minimizing ambient light interference.

Implementation Method 1

a reflective portion (3) constructed to change a traveling direction of light (L) emitted from any one of the plurality of optical fibers (5) from the first direction DIR1 to a second direction DIR2 orthogonal to the first direction

Methodology Applied
Scientific EffectLight reflection: Reflection

Data Source

PatentUS20250172770A1Optical coupler, photoelectric conversion circuit module, and optical transceiver
Publication Date: 2025.05.29 MURATA MFG CO LTD
  • US20250172770A1 patent drawing
  • US20250172770A1 patent drawing
  • US20250172770A1 patent drawing

AI summary

An optical coupler including: an optical fiber fixing portion, a reflective portion that changes a traveling direction of light from a first to a second direction, and a holding portion that holds each of the optical fiber fixing portion and the reflective portion. The holding portion includes a first side wall portion, a second side wall portion, and a third side wall portion positioned on an opposite side of the second side wall portion along a third direction. Each of the optical fiber fixing portion and the reflective portion is connected to each of the second side wall portion and the third side wall portion. At least any one of a width of (1) the first side wall portion along the first direction, (2) the second side wall portion along the third direction, or (3) the third side wall portion along the third direction continuously increases toward the second direction.