Non-Round Optical Ports for Fiber Alignment and Loss Reduction
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Solution Overview
Problem
Existing optical communications modules face challenges in aligning optical fibers with optical ports, leading to potential fiber damage and Fresnel losses due to the round/round interface design, which also prevents the use of refractive index matching epoxy and results in increased costs from non-solder interfaces.
Innovation Solution
The optics system module features non-round, symmetrical optical ports that grip round optical fibers, allowing for precise alignment and the use of refractive index matching epoxy to eliminate air gaps and reduce Fresnel losses, while being capable of withstanding solder reflow processes for surface mount technology integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If round optical ports are used to interface with round optical fibers, then the interface is simple to manufacture, but alignment precision deteriorates and fiber damage risk increases
Solution Approach 1:
The patent applies asymmetry by changing the optical port shape from round to non-round (rectangular or square). This asymmetric shape provides distinct reference edges that enable more precise alignment with the round optical fiber, eliminating the rotational ambiguity inherent in round-to-round interfaces. The non-round port shape creates a unique orientation that simplifies the alignment process while maintaining manufacturing feasibility.
2Loss of energy
If round optical ports are used, then the structure is simple, but Fresnel losses increase due to air gaps
Solution Approach 1:
The non-round optical port shape creates a geometric constraint that naturally guides the refractive index matching epoxy to fill the interface gap between the port and the optical fiber. The asymmetric geometry ensures better epoxy distribution and eliminates air gaps more effectively than round ports, reducing Fresnel losses at the interface.
3Ease of manufacture
If non-solder interfaces are used for mechanical coupling, then the optical module can be assembled, but system cost increases
Solution Approach 1:
The non-round optical port design enables the optical module to be integrated with the system PCB using standard soldering processes. The asymmetric shape provides stable mechanical positioning that maintains connection reliability during solder reflow, allowing the module to withstand the thermal and mechanical stresses of conventional soldering without requiring specialized non-solder interfaces.
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 reduces fiber damage during alignment, minimizes Fresnel losses, and enables the use of surface mount technology, thereby improving optical performance and reducing manufacturing costs.
Implementation Method 1
The first optical port has a non-round shape and is sized to grip a round outer surface of a first optical fiber
Implementation Method 2
allowing for precise alignment and the use of refractive index matching epoxy to eliminate air gaps and reduce Fresnel losses
Implementation Method 3
The optics system module performs the function of directing the optical signals produced by each respective laser diode into the end of a respective transmit optical fiber
Implementation Method 4
The photodiode converts the incoming optical data signal into an electrical signal
Data Source
AI summary
An optics system module for use in an optical communications module is provided that can be more easily aligned with the module during the mounting process, that reduces the possibility of the fiber ends being damaged when they are connected to the respective optical ports of the optics system, and that eliminates or reduces the occurrence of Fresnel losses at the interfaces between the fiber end faces and the optical ports. The optical ports have non-round shapes that are symmetrical to the shapes of the fibers in the transverse direction, i.e., in the direction that is transverse to the optical axes of the fibers. The non-round, symmetrical shape of the optical ports reduces the amount of force that the optical ports exert on the respective optical fibers.