TIR Sub-Assembly with Pre-Aligned Lens for Compact Optical Links
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Solution Overview
Problem
Traditional copper cables face limitations in transmission distance and flexibility at high data rates, necessitating the use of optical fibers for short-distance data links in consumer electronics, which require low-cost, low-power designs for viability.
Innovation Solution
A total internal reflection (TIR) sub-assembly is introduced, comprising a body with a lens and optical turning member, integrated with a carrier and active device, allowing pre-alignment and independent testing, and is designed to reduce the overall stack height and enhance signal-to-noise performance by positioning active and passive components optimally.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If traditional copper cables are used for high data rate transmission, then data transmission capability is achieved, but transmission distance is limited and cable flexibility is reduced
Solution Approach 1:
The patent replaces electrical signal transmission through copper cables with optical signal transmission through fiber optic cables. This substitution enables high data rates (10 Gb/s and above) while extending transmission distance and improving flexibility, directly resolving the technical contradiction between transmission speed and transmission distance
2Reliability
If fiber optic assemblies use expensive high-power edge-emitting lasers with modulators, then transmission performance is improved, but cost increases
Solution Approach 1:
The patent changes the key parameter of the light source from high-power edge-emitting lasers to low-power VCSELs (vertical-cavity surface-emitting lasers). This parameter change maintains adequate transmission performance for short-distance applications while dramatically reducing cost and power consumption, making fiber optic assemblies viable for consumer electronics
Solution Approach 2:
The patent adopts lower-cost VCSELs and simpler optical components that can be manufactured more economically. While these components may have shorter operational lifetimes compared to high-end alternatives, they provide sufficient performance for consumer electronics applications at a fraction of the cost, enabling mass market adoption
3Device complexity
If active devices and lenses are aligned after assembly on printed circuit board, then manufacturing complexity is reduced, but alignment precision and optical performance deteriorate
Solution Approach 1:
The patent implements pre-alignment of active devices and lenses on the carrier board before final assembly onto the printed circuit board. This preliminary alignment action ensures precise optical coupling is achieved during sub-assembly fabrication, maintaining high optical performance while keeping the overall manufacturing process manageable through modular assembly
4Reliability
If optical components are positioned with larger spacing, then heat dissipation and signal interference are improved, but overall assembly size increases
Solution Approach 1:
The patent utilizes three-dimensional spatial arrangement and vertical layering of optical components on the carrier board. By positioning components in multiple dimensions and utilizing vertical spacing, the design achieves adequate heat dissipation and signal isolation without increasing the horizontal footprint, thus maintaining compact overall assembly size while improving signal-to-noise performance
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 TIR sub-assembly reduces the overall profile of fiber optic sub-assemblies, enabling more efficient signal transmission and noise reduction by minimizing the distance between active and passive components, thus addressing the challenges of high data rate transmission in consumer electronics.
Implementation Method 1
a lens supported by the body and positioned in the optical path
Implementation Method 2
an optical turning member supported by the body and configured to change the direction of the optical path
Data Source
AI summary
A total internal reflection sub-assembly includes a body defining at least a portion of an optical path, a lens supported by the body and positioned in the optical path, and an optical turning member supported by the body and configured to change the direction of the optical path. The total internal reflection sub-assembly also includes a carrier having a first surface coupled to the body and a second surface opposite the first surface. An active device is supported on the first surface of the carrier, which is coupled to the body on opposite sides of the active device. The body and carrier are shaped so that a space is maintained between the active device and an underside surface of the body. The lens is positioned on the underside surface and aligned with the active device.