Pentagon Micro-Optics Module for WDM Signal Routing
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Solution Overview
Problem
Current WDM devices face challenges in high manufacturing costs and low yield due to stringent requirements for high-precision control of coatings and precise orientation, leading to wasteful material usage and durability concerns from differing thermal expansion coefficients.
Innovation Solution
A micro-optics module with a pentagon-shaped glass body and strategically attached filters and mirrors, optimized for compactness and efficiency, featuring specific coatings and geometric arrangements to manage optical signals and reduce material waste and thermal issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If WDM filter is placed at 45-degree angle with high-precision control of coating and orientation, then WDM functionality is achieved, but manufacturing cost increases and yield decreases
Solution Approach 1:
The patent employs asymmetric geometric configurations including a 45-degree angled WDM filter surface, 30-degree prism angles, and specifically designed optical path lengths. These asymmetric geometries enable precise optical signal separation while providing manufacturing tolerances that reduce cost and improve yield compared to symmetric high-precision requirements.
Solution Approach 2:
The patent transitions from planar 2D optical paths to 3D spatial configuration by incorporating angled surfaces, prisms, and multi-dimensional optical routing. This dimensional change allows optical signals to be separated in space rather than requiring extremely precise 2D alignment, thereby reducing manufacturing difficulty while maintaining WDM functionality.
2Reliability
If WDM filter is placed at 45-degree angle with high-precision control of coating and orientation, then WDM functionality is achieved, but manufacturing yield decreases
Solution Approach 1:
The patent modifies critical geometric parameters such as setting the WDM filter at 45 degrees, prisms at 30 degrees, and optimizing optical path lengths. These parameter changes create a design that is less sensitive to manufacturing variations, thereby improving yield while maintaining the required WDM functionality.
Solution Approach 2:
The optical system is segmented into distinct functional components (WDM filter, prisms, optical paths) with defined interfaces. This segmentation allows each component to be manufactured and assembled with relaxed tolerances, improving overall manufacturing yield compared to a monolithic high-precision design.
3Reliability
If filters and mirrors are made larger than channel cross-sections for attachment, then durability is improved, but material waste increases
Solution Approach 1:
The patent nests the optical components (filters and mirrors) precisely within the metal structure channels, with component dimensions matched to the channel cross-sections. This nesting approach eliminates the need for oversized components while maintaining secure attachment and durability, thereby reducing material waste.
Solution Approach 2:
The patent applies local quality by making filters and mirrors precisely the size needed for their specific attachment locations within the channels. Rather than using uniformly oversized components, each component is locally optimized to fit its channel, reducing material waste while ensuring durability through precise positioning.
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 module enables cost-effective, high-precision WDM functionality with reduced material loss and improved thermal stability, facilitating mass production and efficient optical signal management.
Implementation Method 1
The WDM coating at second surface 102 is made such that it ensures that only a specific wavelength, such as λ1 of the transmitting optical signal from Tx, may pass through the second surface 102, and λ2 of the receiving optical signal may get reflected at the second surface 102, in a 90-degree angle
Implementation Method 2
WDM filter 100 has a first surface 101 that is often coated with an anti-reflective (AR) coating (or film)
Data Source
AI summary
Embodiment of present invention provide a micro-optics module. The module includes a glass body of pentagon shape having five side surfaces including an upper side surface, a left side and a right side surface next to the upper side surface, a lower side surface next to the left side surface, and a 5th side surface next to and between the lower side surface and the right side surface. The glass body is adapted to, upon incident of a first optical signal at the left side surface, cause the first optical signal to propagate toward and exit the glass body at the right side surface and, upon incident of a second optical signal at the right side surface, cause the second optical signal to reflect back at the left side surface; reflect back at the 5th side surface; and finally exit the glass body at the upper side surface.