Optical Module with Protruding Fiber Block and Mask
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Solution Overview
Problem
Conventional optical modules face challenges in downsizing due to the presence of fiber blocks, which protect optical components from temperature changes and impacts, making it difficult to reduce the overall module size.
Innovation Solution
The optical module design includes a protruding fiber block with a gap between the housing opening and the block, utilizing a small-diameter optical fiber and a mask, such as a thin plate or grease, to cover the gap and reduce forces applied during bending, and incorporates a reinforcing material to prevent damage from movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fiber block is completely housed inside the housing to protect optical components, then the optical components are protected from temperature changes and impacts, but the overall size of the optical module cannot be reduced
Solution Approach 1:
The fiber block is partially extracted from the housing, with its protruding portion extending outside the housing opening. This allows the housing to be downsized while the fiber block maintains its protective function for the optical component through its integrated structure.
Solution Approach 2:
The fiber block is divided into two functional segments: a portion inside the housing that provides structural support and protection, and a protruding portion outside the housing that enables compact housing design. This segmentation resolves the contradiction between protection and size reduction.
2Volume of moving object
If a gap is provided between the opening portion and the fiber block to enable protrusion, then the housing size is reduced, but foreign objects may enter the housing from the gap
Solution Approach 1:
A mask is introduced as an intermediary element between the housing opening and the protruding fiber block. The mask covers the gap to prevent foreign object entry while allowing the fiber block to protrude, thus resolving the contradiction between size reduction and contamination prevention.
3Ease of operation
If the optical fiber is bent to connect components, then connectivity is achieved, but a large bending moment is applied to the fiber block base part causing potential damage
Solution Approach 1:
The optical fiber diameter is changed from the conventional 125 μm to a smaller diameter (80-100 μm). This parameter change reduces the bending moment applied during fiber bending, as the smaller diameter fiber requires less force to bend, thereby protecting the fiber block base part from damage while maintaining connectivity.
4Force
If the optical fiber diameter is reduced to minimize bending moment, then the force applied to the connecting portion is reduced, but the fiber becomes more susceptible to external damage
Solution Approach 1:
A reinforcing material is applied to the fiber block base part before the fiber is installed. This reinforcing material acts as a protective cushion that prevents external damage to the fiber and fiber block connection, compensating for the increased vulnerability caused by using a smaller diameter fiber.
Data Source
AI summary
An optical module that has a structure ensuring reduction in size. The optical module has a structure where a part of a fiber block is protruded from a housing. By including a thin plate, this optical module can avoid entering of dust in the housing, allows a position shift of the fiber block due to a mounting position error of an optical component in the housing, a position shift of an opening portion due to a dimensional error of the housing, or a displacement due to a temperature change, and can reduce the coupling loss due to the optical axis misalignment.