Optical Connector With Spatially Segregated Coupling Regions
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Solution Overview
Problem
Existing optical connectors require tight mechanical alignment, which increases manufacturing and maintenance costs due to sensitivity to mechanical misalignment, making it difficult to efficiently couple multiple optical fibers while maintaining performance.
Innovation Solution
An optical connector with an optical spreader component on a substrate that spatially segregates optical coupling between the optical fiber and the optical component, reducing mechanical alignment requirements by using a first coupling region optically coupled to the fiber and a second coupling region optically coupled to the component, allowing for re-matable mechanical and optical coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tight mechanical alignment is used between optical connectors and optical components, then optical signal reflection is reduced and connector efficiency is improved, but manufacturing cost and complexity increase significantly
Solution Approach 1:
The patent introduces an optical spreader component as an intermediary element between the optical fiber and optical component. This spreader has a first coupling region that receives light from the fiber and a second coupling region that couples to the optical component, with the two regions spatially separated. This intermediary structure decouples the alignment requirements, allowing each interface to have relaxed tolerance while maintaining overall optical performance.
Solution Approach 2:
The optical coupling path is segmented into distinct regions: a first coupling region for fiber connection and a second coupling region for component connection. These regions are spatially separated on the substrate, allowing independent optimization and alignment of each interface without requiring tight overall alignment between fiber and component.
2Manufacturing precision
If precision molded and polished components are used to achieve tight mechanical alignment, then alignment accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The optical spreader acts as a mediator that eliminates the need for precision molded and polished components. By introducing this intermediate element with spatially separated coupling regions, the system achieves optical coupling without requiring the expensive precision manufacturing processes previously needed to maintain tight alignment between fiber and component.
3Quantity of substance
If the number of optical fibers in an optical ribbon cable is increased, then communication capacity is improved, but maintaining mechanical alignment becomes more difficult
Solution Approach 1:
The optical coupling function is segmented across multiple spatially separated coupling regions on the substrate. This segmentation allows each fiber-spreeder-component interface to be independently aligned with relaxed tolerances, making it feasible to handle larger numbers of fibers without proportionally increasing alignment difficulty.
Solution Approach 2:
The patent transitions from one-dimensional linear alignment (fiber directly to component) to a two-dimensional spatial arrangement where coupling regions are distributed across the substrate surface. This dimensional change allows for more flexible alignment and makes it easier to accommodate multiple fibers while maintaining coupling performance.
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 reduces mechanical alignment sensitivity by an order of magnitude, allowing for increased mechanical alignment tolerance, lower manufacturing costs, and improved reliability, enabling efficient coupling of multiple optical fibers and components.
Implementation Method 1
an optical waveguide that is optically coupled to the first coupling region and to the second coupling region
Data Source
AI summary
An optical connector is described. This optical connector spatially segregates optical coupling between an optical fiber and an optical component, which relaxes the associated mechanical-alignment requirements. In particular, the optical connector includes an optical spreader component disposed on a substrate. This optical spreader component is optically coupled to the optical fiber at a first coupling region, and is configured to optically couple to the optical component at a second coupling region that is at a different location on the substrate than the first coupling region. Moreover, the first coupling region and the second coupling region are optically coupled by an optical waveguide.