Fiber Optic Interface Module With TIR Lens Surfaces
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Solution Overview
Problem
Current fiber optic interface modules for short-distance data links in consumer electronics face challenges in achieving high data rates while being cost-effective, reliable, and tolerant to misalignment, as traditional copper cables are limited by transmission distance and size, and existing solutions require complex active alignment processes.
Innovation Solution
A fiber optic interface module design that employs total internal reflection and folded optical paths with integrated lens surfaces, providing misalignment tolerance of ±20 microns or greater while maintaining coupling efficiencies of 85% or greater, and featuring a monolithic body with hyperbolic lens surfaces and passive alignment features for cost-effective and reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If traditional copper cables are used for short-distance data links, then cost and simplicity are maintained, but transmission distance is limited and cable size increases reducing flexibility
Solution Approach 1:
The patent replaces electrical signal transmission through copper cables with optical signal transmission through fiber optic cables. This substitution enables higher data transmission rates (10 Gb/s and beyond) and extends transmission distance while reducing cable size and improving flexibility, directly resolving the technical contradiction between transmission speed and transmission distance
2Speed
If expensive high-power edge-emitting lasers with modulators are used, then high data rates are achieved, but cost increases significantly
Solution Approach 1:
The patent changes the optical parameters by using vertical-cavity surface-emitting lasers (VCSELs) operating at 850 nm wavelength instead of edge-emitting lasers. This parameter change enables high-speed data transmission while significantly reducing cost, as VCSELs are lower-cost, lower-power devices that can be directly modulated, directly resolving the technical contradiction between transmission speed and cost
3Manufacturing precision
If complex active alignment processes are used, then precise optical alignment is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent incorporates preliminary alignment features directly into the module body during manufacturing, including integrated lens surfaces and optical alignment structures. These features are pre-configured to provide mechanical and optical alignment references, enabling passive alignment of optical components without requiring complex active alignment processes, directly resolving the technical contradiction between alignment precision and manufacturing complexity
4Reliability
If misalignment tolerance is increased to ±20 microns or greater, then manufacturing robustness improves, but coupling efficiency may decrease
Solution Approach 1:
The patent employs curved lens surfaces (hyperbolic or spherical) instead of flat surfaces to focus and collimate optical beams. The curved geometry provides inherent beam shaping and focusing capabilities that maintain high coupling efficiency even when component positions vary within ±20 microns tolerance, directly resolving the technical contradiction between misalignment tolerance and coupling efficiency
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 solution enables efficient and reliable high-data-rate transmission over short distances with improved misalignment tolerance and reduced manufacturing complexity, making it suitable for consumer electronics applications.
Implementation Method 1
a ridge having an angled wall that defines a total-internal-reflection (TIR) mirror
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
Fiber optic interface modules and assemblies using same are disclosed, wherein the module includes first and second lenses formed therein that utilize total-internal reflection within the module body. The first and second lenses define first and second optical paths of different lengths. The module may operably support first and second optical fibers so that they are optically coupled to surfaces of the first and second lenses. The first and second lenses are designed to provide predetermined tolerances for lateral offsets relative to first and second active photo-devices while maintaining respective first and second coupling efficiencies between the active photo-devices and the corresponding first and second optical fibers.