Optical Coupler Using Dielectric Interface for Total Internal Reflection
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Solution Overview
Problem
Existing optical couplers face challenges in maintaining insulating properties and optical coupling efficiency due to the use of metallic reflecting films, which degrade the insulation and increase production costs, and are prone to interface peeling issues.
Innovation Solution
An optical coupler design that eliminates the metallic reflecting film by using a translucent primary mold resin with a secondary mold resin of lower refractive index, forming an elliptical surface for total internal reflection between the resins, allowing the light to be guided efficiently between the light emitting and receiving elements without leakage, thereby enhancing insulation and coupling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metallic reflecting film is deposited by sputtering, then the reflecting surface is formed, but the manufacturing complexity and production cost increase
Solution Approach 1:
The patent employs a dielectric reflecting film that can be formed through simpler, more cost-effective manufacturing processes compared to sputtering. This approach uses readily available materials and standard fabrication techniques, reducing production cost while achieving the required reflecting surface quality.
Solution Approach 2:
The patent changes the material parameter from metallic to dielectric, which fundamentally alters the deposition process requirements. Dielectric films can be formed using conventional coating methods rather than requiring vacuum sputtering, thereby simplifying manufacturing and reducing costs.
2Reliability
If an inorganic material layer (metallic reflecting film) is formed at the interface between the primary mold body and secondary mold body, then the reflecting surface is created, but the interface is easily peeled off degrading reliability
Solution Approach 1:
The patent uses a dielectric reflecting film that can be integrated into the mold body structure as a composite material system. The dielectric material forms a unified structure with the mold bodies, eliminating the separate layer that causes peeling issues in metallic film configurations.
Solution Approach 2:
The patent applies the dielectric reflecting film specifically at the interface region where it is needed for optical reflection, while maintaining the structural integrity of the mold bodies. This localized application ensures the reflecting function without compromising the overall structural stability and bonding strength.
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 design improves insulating properties and optical coupling efficiency while reducing production costs by eliminating the need for metallic reflecting films and preventing interface peeling, resulting in a more reliable and cost-effective optical coupler.
Implementation Method 1
the first conversion element and the second conversion element are optically coupled by totally reflecting the optical signal emitted from the first conversion element at an interface between the primary mold resin and the secondary mold resin
Data Source
AI summary
A method for producing the optical coupler includes mounting a first conversion element on an upper surface of a first terminal plate, mounting a second conversion element on an upper surface of a second terminal plate, supplying a translucent primary mold resin in a fluidized state to the upper surfaces of the first terminal plate and the second terminal plate such that the first conversion element and the second conversion element are covered with the primary mold resin, curing the primary mold resin while inverting vertically the first terminal plate and the second terminal plate to retain the primary mold resin in a state in which the primary mold resin hangs from the first terminal plate and the second terminal plate, and covering a surface of the primary mold resin with a secondary mold resin having a refractive index lower than that of the primary mold resin.