Optical Port-Shuffling Module Using TIR Mirrors
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Solution Overview
Problem
Large-scale optical communication systems face challenges in efficiently reordering and routing numerous optical cables due to the complexity and cost associated with traditional optical shuffling methods, which often require mirrored surfaces and complex fabrication processes.
Innovation Solution
The implementation of a monolithic optical port-shuffling module using total-internal-reflection (TIR) mirrors made from materials with a lower refractive index than the optically transmissive body, such as molded plastic, allows for cost-effective and scalable optical signal rearrangement without the need for mirrored surfaces, utilizing injection molding for mass production and selective filling of cavities with index-matching materials to determine reflection paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional optical shuffling methods using mirrored surfaces are employed, then optical signal reordering can be achieved, but manufacturing cost and fabrication complexity increase significantly
Solution Approach 1:
The patent replaces traditional mechanical mirrored surfaces with optically transmissive material blocks that utilize total internal reflection. This substitution eliminates the need for complex mirror coating processes and precise alignment mechanisms, thereby reducing manufacturing cost and fabrication complexity while maintaining optical signal reordering functionality.
Solution Approach 2:
The patent changes the optical parameters of the shuffling module by using materials with specific refractive index relationships (n1 > n2) to enable total internal reflection. This parameter change allows the system to achieve mirror-like reflection functionality through material properties rather than mechanical surfaces, simplifying fabrication and reducing costs.
2Productivity
If traditional optical shuffling methods are used, then optical cable reordering can be performed, but the system becomes less scalable and more expensive for large-scale deployments
Solution Approach 1:
The patent segments the optical shuffling function into multiple independent optically transmissive material blocks, each handling specific signal routing tasks. This segmentation allows for modular manufacturing and deployment, enabling scalable expansion from small to large-scale optical networks without proportionally increasing complexity or cost.
Solution Approach 2:
The patent enables replication of the optically transmissive material block design across multiple units. Once a shuffling configuration is designed and validated, it can be copied and manufactured at scale using standard optical fabrication processes, significantly reducing per-unit costs for large-scale deployments compared to traditional custom-mirror systems.
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 provides a low-cost, highly scalable, and efficient optical shuffling mechanism that is insensitive to frequency and polarization, enabling rapid and inexpensive production of optical port-shuffling modules capable of handling large quantities of optical signals in datacenter networks.
Implementation Method 1
the optically transmissive material block can include a plurality of total-internal-reflection (TIR) mirrors arranged to reflect a respective one of the optical signals to a corresponding one of the outputs
Implementation Method 2
The TIR mirrors can have a refractive index that is less than a refractive index of the optically transmissive material from which the body portion is fabricated
Data Source
AI summary
One example includes an optical port-shuffling module. The module includes a plurality of inputs to receive a respective plurality of optical signals. The module also includes a plurality of outputs to provide the respective plurality of optical signals from the optical port-shuffling module. The module further includes a plurality of total-internal-reflection (TIR) mirrors arranged in optical paths of at least a portion of the plurality of optical signals to reflect the at least a portion of the plurality of optical signals to at least a portion of the plurality of outputs to shuffle the plurality of optical signals between the plurality of inputs and the plurality of outputs.