Optical Interface Module With Micro-Lens Array
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Solution Overview
Problem
Existing optical interface modules face challenges in efficiently transferring and receiving high-speed optical signals between optical fibers and electronic equipment, particularly due to mechanical damage and reduced reliability caused by protruding fiber ends during assembly, and limitations in maintaining high bandwidth with small form factor and low power consumption.
Innovation Solution
The optical interface module incorporates a light rotation module with perpendicularly mounted optical ferrules and lenses to bend and couple optical signals, using micro-lenses to compensate for signal divergence and prevent mechanical damage by keeping fiber ends flush with the ferrule edge, ensuring reliable and efficient signal transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If fiber ends are allowed to protrude from ferrule edges for easier assembly, then assembly ease is improved, but mechanical damage and reliability deteriorate
Solution Approach 1:
The patent introduces micro-lenses as an intermediary component between the fiber ends and the ferrule edges. The micro-lenses are mounted on the ferrule surface with their optical axes aligned to the fiber cores, allowing the fiber ends to be positioned flush with or recessed from the ferrule edges while maintaining proper optical coupling. This mediator enables assembly ease without compromising mechanical protection or optical performance.
Solution Approach 2:
The patent transitions from a traditional side-by-side fiber-ferrule arrangement to a stacked configuration where fiber ends are positioned vertically flush with ferrule edges. By combining this vertical positioning with micro-lens coupling, the design achieves compact form factor while preventing mechanical damage to protruding fibers.
2Manufacturing precision
If micro-lenses are added to compensate for signal divergence, then optical coupling efficiency is improved, but device complexity increases
Solution Approach 1:
The patent modifies the optical parameters by introducing micro-lenses with specific focal lengths and mounting positions optimized for the fiber-to-transducer coupling. The micro-lenses compensate for signal divergence caused by the perpendicular mounting configuration, maintaining high optical coupling efficiency despite the changed geometric arrangement.
Solution Approach 2:
The patent integrates the micro-lenses directly onto the ferrule structure, merging the coupling function into the existing ferrule component rather than adding separate coupling mechanisms. This integration approach minimizes the increase in device complexity while achieving the required optical coupling efficiency.
3Volume of moving object
If perpendicular mounting of ferrules is used to achieve compact form factor, then volume is reduced, but optical signal transfer difficulty increases
Solution Approach 1:
The patent adopts a perpendicular (stacked) mounting configuration for ferrules instead of traditional side-by-side arrangement. This vertical stacking reduces the horizontal footprint and overall module volume while the micro-lenses facilitate optical coupling between the perpendicular fiber ends and transducer arrays.
Solution Approach 2:
The micro-lenses serve as intermediaries that enable optical signal transfer between the perpendicular ferrule configurations. By positioning the micro-lenses at appropriate locations on the ferrules and aligning their optical axes with the fiber cores, the patent overcomes the optical path challenges introduced by the perpendicular mounting arrangement.
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 the reliability and manufacturing yield of optical interface modules by preventing mechanical damage, maintaining high bandwidth, and achieving a compact form factor with low power consumption, supporting high-speed data rates like 14 Gbps and 25 Gbps.
Implementation Method 1
The lenses are mounted between the first ferrule and the first holes, so as to couple the first optical signals via the first holes between the first ferrule and the first optical transducers
Implementation Method 2
the one or more lenses are configured to compensate for a divergence of the first optical signals traversing the first holes
Data Source
AI summary
An apparatus includes a connector that connects to optical fibers for connecting first and second optical signals to the apparatus. A first optical ferrule is mounted perpendicularly to the connector, and transfers the first optical signals between the connector and first optical transducers mounted on a first substrate, via first holes formed in the first substrate. A second optical ferrule is mounted perpendicularly to the connector, and transfers the second optical signals between the connector and second optical transducers mounted on a second substrate, via second holes formed in the second substrate. A light rotation module bends and transfers the first and second optical signals between the connector and the first and second ferrules. One or more lenses are mounted between the first ferrule and the first holes, so as to couple the first optical signals via the first holes between the first ferrule and the first optical transducers.