PCB Optical Connector Assembly with Blind-Mate Alignment
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Solution Overview
Problem
The existing methods for optically connecting components on a printed circuit board (PCB) are prone to damage, costly, and time-consuming, especially when using optical fibers and connectors, and the integration of optical infrastructure into PCBs increases manufacturing costs and makes them unsuitable for high-volume, low-cost applications.
Innovation Solution
A PCB assembly that integrates optical and electrical infrastructure, featuring a connector assembly with protected optical fibers and a blind-mate floating optical connector for quick and reliable assembly, along with guiding features for alignment, and a heat-sink for thermal management, allowing for both optical and electrical coupling with the PCB.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If optical fibers and connectors are used for high data rate signal transmission, then signal integrity and data rate are improved, but assembly time and production cost increase
Solution Approach 1:
The patent applies preliminary action by pre-attaching optical connectors to the optical fibers during PCB manufacturing, so that when components are mounted, the optical connections are already in place. This eliminates the need for separate connector installation steps, reducing assembly time while maintaining signal integrity through proper pre-positioning of connectors.
Solution Approach 2:
The patent merges the optical connection infrastructure with the PCB structure by integrating optical fibers and connectors directly into the board during manufacturing. This combination of electrical and optical infrastructure into a single integrated platform reduces the number of separate assembly steps and components, thereby reducing overall assembly time while preserving high data rate transmission capabilities.
2Reliability
If optical connectors are manually installed and engaged, then optical connection is achieved, but assembly time increases and connection reliability decreases
Solution Approach 1:
The patent replaces manual mechanical connector installation with an automated integration process during PCB manufacturing. Optical fibers and connectors are pre-positioned and fixed to the PCB using automated placement and curing systems, eliminating manual handling. This substitution increases connection reliability through consistent positioning while dramatically reducing assembly time through automation.
Solution Approach 2:
The patent applies preliminary action by pre-attaching optical connectors to the optical fibers during PCB manufacturing, so that when components are mounted, the optical connections are already in place. This eliminates the need for separate connector installation steps, reducing assembly time while maintaining signal integrity through proper pre-positioning of connectors.
3Ease of operation
If optical fibers are exposed during assembly, then connection flexibility is maintained, but optical infrastructure is prone to damage
Solution Approach 1:
The patent applies preliminary action by pre-protecting optical fibers with protective coatings and pre-positioning them in protected channels within the PCB structure during manufacturing. This preliminary protection measures ensure that fibers remain protected throughout the assembly process while maintaining their optical transmission properties and connection capabilities.
Solution Approach 2:
The patent implements beforehand cushioning by incorporating protective buffer layers and flexible protective sheathing around optical fibers before they are subjected to assembly stresses. These pre-applied protective elements absorb mechanical stresses and prevent damage to the fragile optical infrastructure while allowing the necessary flexibility for connection.
4Object-affected harmful factors
If pivotable connector mechanism is used to protect optical fibers, then optical infrastructure is protected, but device complexity and production cost increase
Solution Approach 1:
The patent extracts the protective function from complex mechanical pivotable connector mechanisms and implements it through simpler integrated PCB structures. Optical fibers are embedded in protective channels and coated with protective materials directly during PCB manufacturing, eliminating the need for separate mechanical protection systems while maintaining adequate protection from damage.
Solution Approach 2:
The patent replaces expensive, complex pivotable connector mechanisms with simpler, cost-effective protective structures integrated into the PCB. The protective function is achieved through material coatings and structural design rather than complex mechanical systems, reducing device complexity and production cost while providing sufficient protection for the optical infrastructure.
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 solution provides a convenient, quick, and reliable assembly method that protects optical infrastructure from damage, reduces production costs, and enables efficient high-data-rate signal transmission while maintaining the integrity of the optical components.
Implementation Method 1
a heat-sink for thermal management
Data Source
AI summary
An optoelectronic assembly for a printed circuit board (PCB) assembly is described herein. The optoelectronic assembly may include a component carrier for mounting an active component, and a connector assembly for achieving a coupling between the component carrier and PCB-side optical infrastructure on a printed circuit board (PCB). The connector assembly can include a plurality of optical fibers connected to the component carrier, a first optical connector connected to the optical fibers for coupling with the PCB-side optical infrastructure on the PCB, and a housing member for housing the optical fibers and the first optical connector.