Thermal Protective Layer for Optical Module Heat Dissipation
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Solution Overview
Problem
High-power optical modules in communications networks generate excessive heat, making them unsafe for human touch during online insertion and removal due to limited heat sinking surfaces and ineffective heat conduction, with surface temperatures often exceeding 55°C, posing a risk for technicians.
Innovation Solution
A thermal protective layer is applied to the optical modules, comprising a sleeve or raised elements that prevent direct contact with the external surface while allowing heat dissipation through openings, ensuring safe handling and temperature control by exposing the surface to ambient air.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high-power optical modules are used to increase communication performance, then energy use and heat dissipation increase, but surface temperature becomes unsafe for human touch
Solution Approach 1:
A thermal protective layer is introduced as an intermediary between the hot optical module surface and human skin. This layer acts as a thermal insulator that prevents direct heat transfer to the user while allowing the module to maintain high power operation. The protective layer is transparent to maintain aesthetic appearance while providing thermal protection.
Solution Approach 2:
The patent applies a thin film thermal protective coating on the optical module surface. This flexible thin layer provides thermal insulation without significantly affecting the module's physical dimensions or heat dissipation capability. The thin film structure allows the module to maintain its form factor while protecting users from high surface temperatures.
2Object-affected harmful factors
If thermal protective layer is applied to prevent direct contact, then safety is improved, but heat dissipation capability must be maintained
Solution Approach 1:
The thermal protective layer incorporates a porous structure that allows heat to pass through via convection and radiation while maintaining thermal insulation properties. The porous architecture enables air circulation that facilitates heat dissipation from the module surface, preventing heat buildup while still protecting users from direct contact with hot surfaces.
Solution Approach 2:
The protective layer uses composite material structure combining thermal insulation properties with heat dissipation capabilities. The composite design allows the layer to block direct thermal conduction to users while permitting radiative and convective heat loss from the module, thus maintaining both safety and thermal management.
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
The thermal protective layer effectively reduces thermal exposure during module removal, maintaining a safe touch temperature below 55°C and allowing for efficient heat dissipation, thereby ensuring technician safety and module reliability in high-temperature environments.
Implementation Method 1
a thermal protective layer extending over at least a portion of the second end of the optical module, the thermal protective layer preventing direct contact with an external surface of the optical module
Implementation Method 2
The thermal protective layer exposes a portion of the external surface of the second end of the optical module to allow heat to be released from the external surface of the optical module
Data Source
AI summary
In one embodiment, an apparatus includes an optical module comprising a first end for insertion into a network device and a second end extending from the network device when the optical module is inserted into the network device, and a thermal protective layer extending over a portion of the second end of the optical module, the thermal protective layer preventing direct contact with an external surface of the optical module during removal of the optical module from the network device. The thermal protective layer exposes a portion of the external surface of the second end of the optical module to allow heat to be released from the external surface of the optical module.