Optoelectrical Connector Decoupled Alignment
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Solution Overview
Problem
Existing optoelectrical connector systems face challenges in accurately aligning with photonic devices on printed circuit boards due to tight tolerances, requiring complex molding operations and precise alignment of multiple components.
Innovation Solution
The optoelectrical connector system consists of a separate optical coupler and connector housing, where the coupler is first precisely aligned with the photonic device on the PCB, and then the housing is attached, allowing for a decoupled alignment process that does not require tight tolerances for the housing, using alignment tabs, slots, and adhesive for secure fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the connector housing and optical coupler are integrated as a single molded component, then manufacturing precision can be improved, but device complexity and manufacturing cost increase due to complex molding operations
Solution Approach 1:
The connector system is divided into two separate components: a connector housing and an optical coupler. The optical coupler is mounted separately on the PCB and aligned with the photonic device, while the housing is attached afterward. This segmentation allows the optical alignment to be performed on the coupler alone, avoiding the need for complex integrated molding operations while maintaining high alignment precision.
2Manufacturing precision
If tight tolerances are applied to all components including the housing, then alignment precision is improved, but manufacturing cost increases
Solution Approach 1:
Different tolerance requirements are applied to different components based on their functional requirements. The optical coupler, which directly interfaces with the photonic device, is manufactured with tight tolerances to ensure precise optical alignment. The connector housing, which provides mechanical support and protection, is manufactured with looser tolerances, reducing its manufacturing cost while not affecting optical performance.
3Ease of operation
If the housing is attached before mounting the coupler, then assembly is simplified, but alignment precision deteriorates due to accumulated tolerances
Solution Approach 1:
The optical coupler is mounted and aligned with the photonic device on the PCB before the connector housing is attached. This preliminary action ensures that the critical optical alignment is established with high precision on the coupler itself, independent of the housing's position. The housing is then attached to the already-aligned coupler, simplifying the overall assembly process while maintaining alignment precision.
Data Source
AI summary
An optoelectrical connector system can include an optical coupler that is configured to be positioned over a photonic device on the PCB. The optoelectrical connector system can further include a connector housing that is configured to be attached to the optical coupler after the optical coupler is positioned over the photonic device, so that the coupler can be aligned and fixed without the housing attached thereto.