Pluggable Optical Modules With Blind Mate Connectors
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Solution Overview
Problem
Co-packaged optics (CPO) applications face challenges such as reduced flexibility in optical interfaces, thermal issues, and reliability risks due to the integration of lasers with other optical hardware, which complicates operational management and maintenance.
Innovation Solution
A pluggable optical device with a housing, printed circuit board (PCB), blind mate optical connectors, and electrical contacts that allows for remote laser sources to be easily replaced, addressing thermal concerns and improving reliability, while enabling high system density and flexible integration with existing cooling and power systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If lasers are co-located with other optical hardware in CPO applications, then integration density is improved, but thermal management becomes more difficult and reliability decreases
Solution Approach 1:
The optical module is segmented into distinct functional components: laser sources, optical components, and electrical components are separated and mounted on different substrates (first substrate for optical, second substrate for electrical). This segmentation allows independent thermal management of the laser sources while maintaining high integration density through the stacked configuration.
Solution Approach 2:
The patent transitions from planar integration to three-dimensional stacked integration. Multiple optical modules are stacked vertically with interconnection structures enabling optical and electrical coupling between layers. This vertical dimension allows thermal separation while maintaining compact form factor and high density.
2Adaptability or versatility
If lasers are co-located with other optical hardware in CPO applications, then integration density is improved, but reliability decreases due to compounded risks
Solution Approach 1:
By segmenting the module into separate optical and electrical subsystems on different substrates, the patent isolates failure modes. If one component fails, the modular architecture allows for targeted replacement without affecting the entire system, thereby improving reliability while maintaining integration density.
Solution Approach 2:
The pluggable module design enables easy replacement of failed components. Entire modules or individual substrates can be quickly swapped out and replaced with new units, minimizing system downtime and improving overall reliability through rapid recovery from failures.
3Use of energy by moving object
If traditional CPO applications are used, then lower power and cost are achieved, but operational flexibility is reduced
Solution Approach 1:
The pluggable module design introduces dynamic reconfigurability to the system. Modules can be hot-swapped, added, or removed based on operational requirements. The system can be dynamically reconfigured by changing module configurations, providing operational flexibility while maintaining the power efficiency of integrated CPO architectures.
4Volume of moving object
If lasers are integrated with other optical hardware, then compact design is achieved, but maintenance complexity increases
Solution Approach 1:
The segmented modular architecture simplifies maintenance by isolating components into replaceable units. Rather than servicing individual components within an integrated assembly, technicians can replace entire modules or substrates, reducing maintenance complexity despite the compact overall design.
Solution Approach 2:
The design enables rapid replacement of failed modules or substrates without complex disassembly. Maintenance personnel can quickly swap out problematic components, reducing mean time to repair despite the compact integrated form factor.
Data Source
AI summary
Aspects include a pluggable optical device and related optical system. The pluggable optical device comprises a housing, a printed circuit board (PCB) within the housing, and one or more blind mate optical connectors attached to the PCB along a first end of the PCB. The pluggable optical device further comprises one or more electrical contacts of the PCB near the first end, one or more external optical connectors arranged near a second end of the PCB opposite the first end, and one or more optical components attached to the PCB and included in optical paths extending between the one or more external optical connectors and the one or more blind mate optical connectors.