Molded Plastic Leadframe AOC Connector Design
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Solution Overview
Problem
Active optical cables (AOCs) currently rely on optical connectors, which are expensive, have large form factors, and are limited by temperature range due to thermal expansion mismatch between epoxy encapsulation and metal components, leading to increased costs and reduced operational flexibility.
Innovation Solution
An AOC connector with a molded plastic leadframe and optically-transparent adhesive, eliminating the need for optical connectors, allowing for a wider temperature range and more temperature cycles by integrating optoelectronic elements and bond wires within a plastic molded plug body, reducing mechanical stress and enabling a more compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If optical connectors are used in AOC connectors, then mechanical coupling and securing functionality is achieved, but production costs increase and form factor becomes large
Solution Approach 1:
The patent extracts and eliminates the optical connector component from the AOC connector assembly. Instead of using a separate optical connector that couples to the optical fiber, the invention integrates the optical fiber coupling function directly into the molded plug body through an optical interface formed during the molding process, thereby removing the need for expensive optical connectors while maintaining mechanical coupling functionality
Solution Approach 2:
The patent merges the functions of the optical connector housing and the optical fiber coupling mechanism into a single molded plug body. The optical interface is formed as an integral part of the molded plug body, combining what were previously separate components (optical connector housing + optical fiber attachment mechanism) into one unified structure, reducing both cost and complexity
2Strength
If epoxy encapsulation is used to mount optoelectronic elements, then mechanical support is provided, but thermal expansion mismatch causes stress on bond wires at temperature extremes
Solution Approach 1:
The patent changes the material parameter (coefficient of thermal expansion) by replacing epoxy encapsulation with a molded plastic body material that has a CTE more closely matched to metal components and bond wires. This parameter change reduces thermal expansion mismatch at temperature extremes, thereby reducing stress on bond wires and improving reliability while maintaining mechanical support functionality
Solution Approach 2:
The patent uses a composite construction where the molded plug body integrates multiple materials and structures: the plastic body itself, metal leadframe, and optical elements, all coupled together in a way that accommodates thermal expansion differences. The molded plastic serves as a composite structure that provides mechanical support while having thermal properties more compatible with the metal components than epoxy would provide
3Ease of operation
If optical connectors are used in AOC connectors, then optical fiber coupling is achieved, but the form factor becomes large
Solution Approach 1:
The patent applies the nesting principle by integrating the optical fiber coupling interface directly within the molded plug body structure. The optical interface is formed as a cavity or feature nested within the molded plug body, eliminating the need for an external optical connector housing. This nested integration maintains optical fiber coupling functionality while significantly reducing the overall form factor of the connector assembly
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 reduces production costs, eliminates mechanical stress on bond wires, and expands the operational temperature range and cycle durability of AOCs, making them more cost-effective and reliable.
Implementation Method 1
an adhesive material that is transparent to an operating wavelength of the AOC
Data Source
AI summary
An AOC connector is provided that has a molded plastic leadframe that obviates the need to use an optical connector in the AOC and that is capable of operating over a wide temperature range and a large number of temperature cycles. The AOC connector includes a plastic optical port that is adapted to be connected via an optically-transparent adhesive material to an end of an optical fiber cable.