Ruggedized Optical Sub-Assembly for Avionics Weight Reduction
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Solution Overview
Problem
Current aircraft data bus architectures, such as the ARINC 629, require individually packaged optical media converters and star couplers with bulky and costly connectors, leading to increased weight, cost, and optical attenuation, as well as complex installation and maintenance processes.
Innovation Solution
A low-cost, connectorless, ruggedized optical sub-assembly (OSA) and data bus-in-a-box (BiB) design that uses a POF lock nut and a high-precision, molded polymer package body to embed laser transmitters and receivers, eliminating the need for connectors and simplifying the assembly process while maintaining optimal optical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individually packaged optical media converters and star couplers with connectors are used, then optical signal transmission is achieved, but weight increases and cost increases
Solution Approach 1:
The patent combines multiple optical media converters and star couplers into a single integrated optical sub-assembly package. This merging eliminates the need for separate connectors and cable assemblies, reducing overall system weight while maintaining optical signal transmission capability through direct coupling of optical components within the integrated package.
Solution Approach 2:
The integrated optical sub-assembly performs multiple functions simultaneously - it acts as both optical media converters and star couplers in a single unit. This multi-functionality eliminates the need for separate dedicated components for each function, thereby reducing total component count, weight, and complexity of the optical distribution system.
2Reliability
If individually packaged optical media converters and star couplers with connectors are used, then optical signal transmission is achieved, but cost increases
Solution Approach 1:
By merging multiple optical functions into a single integrated package, the patent reduces the total number of individual components that need to be manufactured, tested, and assembled. This consolidation lowers manufacturing costs through economies of scale and reduced assembly complexity, while maintaining reliable optical signal transmission through precision-integrated optical pathways.
Solution Approach 2:
The patent extracts and eliminates the connector components from the optical signal path, retaining only the essential optical transmission functionality within the integrated package. This extraction removes the cost associated with connector manufacturing, assembly, and maintenance while preserving the core optical signal transmission capability.
3Reliability
If connectors are used in optical packages, then optical signal transmission is achieved, but optical attenuation increases
Solution Approach 1:
The patent removes connectors from the optical signal path entirely, extracting only the necessary optical transmission functionality. This elimination of connectors directly reduces optical attenuation at connection points, improving the optical power budget while maintaining reliable signal transmission through direct optical coupling within the integrated package.
4Reliability
If individually packaged optical media converters and star couplers are used, then optical signal transmission is achieved, but device complexity increases
Solution Approach 1:
The patent merges multiple optical media converters and star couplers into a single integrated optical sub-assembly, dramatically reducing system complexity. This consolidation eliminates the need for multiple separate packages, mounting brackets, rails, and interconnecting cables, simplifying both the physical architecture and the assembly process while maintaining full optical signal transmission functionality.
5Strength
If custom designed support brackets and rails are used to mount optical packages, then secure mounting is achieved, but device complexity and cost increase
Solution Approach 1:
By consolidating multiple optical components into a single integrated package, the patent eliminates the need for separate custom-designed support brackets and rails for each individual component. The integrated package can be mounted as a single unit using simplified mounting structures, reducing mechanical complexity while maintaining secure mounting through the unified package design.
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3B
AI summary
Systems, methods, and apparatus for an optical sub-assembly (OSA) are disclosed. In one or more embodiments, the disclosed apparatus involves a package body, and a lock nut, where a first end of the lock nut inserted into a first cavity of the package body. The apparatus further involves a transistor outline (TO) can, where a first end of the TO can is inserted into a second cavity of the package body. Also, the apparatus involves an optical fiber, where a portion of the jacket from an end of the optical fiber is stripped off, thereby exposing bare optical fiber at the end of the optical fiber. The end of the optical fiber is inserted into a second end of the lock nut such that the bare optical fiber passes into the package body and at least a portion of the bare optical fiber is inserted into the TO can cavity.