Optical Cable Waveguide Layer Reordering via Off-Center Design
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Solution Overview
Problem
Current optical cable systems face challenges in reordering waveguide layers without increasing thickness or bulk, and existing methods such as twisting, bending, or using optical vias are either difficult or undesirable due to entanglement issues and additional losses.
Innovation Solution
The optical cable design features waveguides with off-center center portions, allowing for overlay and interweaving to reroute connections between connectors, enabling reordering without twisting or bending, and eliminating the need for optical vias.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If waveguide layers are reordered by twisting and bending, then layer reordering is achieved, but cable bulk increases excessively
Solution Approach 1:
The patent introduces optical vias that extend in the vertical dimension (z-axis) to connect waveguide layers at different heights. This allows reordering of waveguide layers by routing them through different vertical positions and connecting via optical vias, rather than twisting or bending them in the horizontal plane, thereby achieving layer reordering without increasing cable bulk.
Solution Approach 2:
Optical vias serve as intermediary components that facilitate the connection between waveguide layers. Instead of directly twisting or bending waveguides to reorder them, the optical vias act as mediators that transfer optical signals between layers at different positions, enabling reordering while maintaining a compact cable structure.
2Adaptability or versatility
If optical vias are introduced between waveguide layers, then layer redistribution is facilitated, but additional optical loss occurs and fabrication cost increases
Solution Approach 1:
The patent optimizes the parameters of optical vias, including their dimensions, positioning, and coupling mechanisms, to minimize optical insertion loss. By carefully controlling the via diameter, depth, and alignment with waveguides, the optical coupling efficiency is maximized, reducing the additional loss introduced by the vias.
3Adaptability or versatility
If waveguide layers are bent or twisted for reordering, then layer reordering is achieved, but the process becomes difficult and undesirable
Solution Approach 1:
The patent moves the reordering operation from the horizontal plane to the vertical dimension by using optical vias. Waveguide layers can be stacked in different vertical positions and connected via vias, which simplifies the manufacturing process compared to twisting or bending waveguides, as the vias can be formed using standard vertical etching and filling processes.
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 approach results in a thin, flexible optical cable that simplifies wiring, reduces entanglement, and preserves 2D planarity, offering multiple reordering options while minimizing optical losses.
Implementation Method 1
Light is guided in a core (optical channels) due to the index contrast between the core and clad regions
Data Source
AI summary
An optical cable including connectors includes a plurality of waveguide layers each including a plurality of optical channels each having a first end and a second end. First and second connectors each include a plurality of electrically conductive pins, and each of the plurality of optical channels of each of the waveguides, at their first and second ends, are connected to a specified pin on each of the first and second connectors, respectively. A first optical channel connection pattern on the first connector, and a second optical channel connection pattern on the second connector. The first optical channel connection pattern on the first connector is a different pattern than the second optical channel connection pattern on the second connector in relation to a connection hole pattern which is the same for both the first and second connectors.