Plastic Optical Fiber Links for Embedded Applications
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Solution Overview
Problem
Current fiber optic links for consumer applications are too large and costly to meet the requirements of small size and low cost while maintaining high performance, especially for embedded applications in devices like laptops and televisions, where they need to operate at speeds of 1 Gbps or faster and are susceptible to electromagnetic interference.
Innovation Solution
The development of novel plastic optical fiber data communication links with unique packaging approaches, featuring a compact design with a circuit board size as small as 2.2 mm×3.5 mm, incorporating a VCSEL, driver circuit, photodetector, and optical coupler, which uses a flexible plastic fiber with a small bend radius and easy termination, and includes a metal or plastic machined coupler for efficient light coupling, along with a protective ridge to prevent damage and reduce handling costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fiber optic links are used for consumer applications, then high performance and electromagnetic interference protection are achieved, but size and cost become too large
Solution Approach 1:
The patent changes the fiber material parameter from glass to plastic, which enables smaller core diameter (50-200 μm vs. traditional glass fiber), allowing for compact E-O terminal design while maintaining 1 Gbps or faster data rates. This parameter change directly reduces the overall size of the fiber optic link for embedded applications.
Solution Approach 2:
The patent divides the E-O terminal into separate functional modules (laser/photodetector in first level package, driver circuit and amplifier in second level package) that can be independently packaged and then mounted on a small circuit board. This segmentation allows each component to be optimized and packaged efficiently, contributing to the overall compact design.
2Reliability
If traditional fiber optic links are used for consumer applications, then high performance is achieved, but cost becomes too high
Solution Approach 1:
Switching from glass to plastic optical fiber enables easier and less expensive fiber termination while maintaining adequate performance for consumer applications. The plastic fiber's properties allow for simpler handling and termination processes, reducing manufacturing complexity and cost.
Solution Approach 2:
The patent employs disposable or low-cost components such as plastic optical fiber, molded plastic couplers, and inexpensive VCSELs and photodetectors that can be mass-produced. These components are designed to be cost-effective for consumer electronics where extreme durability is not required, but performance at 1 Gbps or faster is achieved.
3Volume of moving object
If compact design is implemented for embedded applications, then size is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent introduces an optical coupler (molded plastic or machined) as an intermediary component between the laser/photodetector and the fiber. This coupler provides built-in alignment features and tolerance compensation, allowing for proper optical coupling without requiring extremely tight manufacturing tolerances on the individual components. The coupler acts as a mediator that accommodates alignment variations.
Solution Approach 2:
The optical components (laser and photodetector) are pre-packaged in first level packages with built-in alignment features before being mounted on the circuit board. This preliminary packaging and alignment reduces the alignment complexity during final assembly, as the components are pre-positioned and pre-aligned relative to each other, leaving only the fiber coupling to be adjusted.
4Ease of manufacture
If flexible plastic fiber is used, then ease of termination and handling are improved, but optical loss may increase
Solution Approach 1:
The patent optimizes the plastic fiber parameters including core diameter (50-200 μm), cladding diameter, and refractive index profile to achieve adequate optical transmission for 1 Gbps or faster data rates. By carefully selecting these parameters, the patent maintains acceptable optical loss while preserving the ease of termination and handling advantages of plastic fiber.
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 enables high-performance, low-cost, and compact fiber optic links that can operate at 1 Gbps or faster, reducing electromagnetic interference and simplifying assembly with moderate precision, thus addressing the size and cost constraints of traditional fiber optic links for consumer electronics.
Implementation Method 1
a laser, in particular a Vertical-Cavity Surface-Emitting Laser (VCSEL)
Implementation Method 2
a photodetector that receives the light and converts it to an electrical signal
Implementation Method 3
The fiber optic links consist of a detachable optical fiber
Data Source
AI summary
Plastic optical fiber data communication links. Particularly, plastic optical fiber data communication links for embedded applications. More particularly, unique packaging approaches to constructing a very small, low cost, but high performance optical link, which may operate at 1 gigabits per second (Gbps) or faster.