Optical Waveguide Structure for Cost-Effective Manufacturing
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Solution Overview
Problem
Traditional manufacturing techniques for optoelectronic connectors, particularly optical jumpers, result in high production costs due to expensive manufacturing procedures, which are then reflected in the overall cost of datacenter switch systems and associated networking modules.
Innovation Solution
A method for manufacturing optical waveguide structures and optical jumpers using a base member with trenches for an optical transmission medium and channels for adhesive, where a lid member is placed to cover these components, allowing for capillary filling of the medium and adhesive, reducing costs through non-traditional processing methods like hot embossing and machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing techniques are used for optical jumpers, then manufacturing precision and reliability are maintained, but production costs increase significantly
Solution Approach 1:
The optical jumper is divided into separate components: a base member with molded trenches and channels, a lid member, and separately introduced optical transmission medium and adhesive. This segmentation allows each component to be manufactured independently using cost-effective molding processes rather than expensive traditional fabrication techniques.
Solution Approach 2:
The patent changes the physical state of materials during assembly - introducing optical transmission medium and adhesive in liquid form that then cure to solid state. This parameter change enables simple molding processes to create complex internal structures without requiring precision fabrication of each feature separately.
2Ease of manufacture
If traditional optical jumper manufacturing is used, then optical signal transmission quality is ensured, but production complexity and cost increase
Solution Approach 1:
Multiple features (trenches for optical medium, channels for adhesive, alignment structures) are merged into a single base member mold cavity. This consolidation allows all features to be created simultaneously in one molding operation, dramatically reducing manufacturing complexity compared to traditional multi-step fabrication processes.
Solution Approach 2:
The mold structure itself creates the trenches and channels during molding, eliminating the need for separate machining or fabrication steps. The optical transmission medium and adhesive are introduced through reservoirs that are part of the molded structure, allowing self-contained assembly without complex external tooling.
3Productivity
If conventional optical jumper production methods are used, then optical transmission performance is maintained, but manufacturing time and productivity are reduced
Solution Approach 1:
The base member is pre-formed with all necessary trenches, channels, and reservoirs during the molding process before assembly. This preliminary action eliminates time-consuming post-processing steps and allows rapid assembly by simply introducing the optical transmission medium and adhesive, significantly improving production efficiency while maintaining transmission reliability.
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 approach reduces production costs by utilizing capillary flow for filling and machining techniques, enabling cost-effective optical waveguide structures that maintain efficient optical signal transmission while being compatible with existing optoelectronic connectors.
Implementation Method 1
The liquid optical transmission medium and the liquid adhesive may fill the plurality of trenches and the one or more channels, respectively, via capillary flow
Data Source
AI summary
Methods and associated apparatuses are described that provide an optical waveguide structure configured for use within an optoelectronic connector. The optical waveguide structure includes a base member having a first surface defining a plurality of trenches including an optical transmission medium and one or more channels including an adhesive material. The optical waveguide structure includes a lid member having a first surface, where the first surface of the lid member is disposed against the first surface of the base member to form the optical waveguide structure. The one or more channels having the adhesive material serve to secure the lid member to the base member, and the plurality of trenches having an optical transmission medium allow optical signals to pass therethrough.