Optical Transceiver Roughened Mounting Surface Reduces Internal Reflections
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Solution Overview
Problem
Optical transceivers experience transmission failures at high temperatures (≥85° C.) due to internal reflections, which are difficult to identify and pin-point, leading to manufacturing yield issues.
Innovation Solution
The optical transceiver design incorporates a roughened and/or darkened optics mounting surface, a beam splitter, and bandpass filters to reduce internal reflections, with the roughening process involving sand-blasting and the darkening using a dark sealant or coating that absorbs light, and the assembly method includes securing a beam splitter mount and optical subassemblies within the transceiver.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a smooth optics mounting surface is used, then manufacturing is easier, but internal reflections occur causing transmission failures at high temperatures
Solution Approach 1:
The patent changes the surface roughness parameter of the optics mounting surface from smooth to rough (with specific roughness values of 0.002 to 0.010 inches). This parameter change reduces internal reflections and eliminates transmission failures at high temperatures, directly resolving the contradiction between reliability and ease of manufacture.
2Reliability
If internal reflections are not addressed, then device complexity remains low, but transmission failures occur at high temperatures
Solution Approach 1:
The patent applies surface roughness parameter changes to the optics mounting surface, creating a simple yet effective solution that reduces internal reflections without adding complex components or structures, thereby improving reliability while maintaining low device complexity.
3Reliability
If conventional testing is used, then manufacturing yield appears acceptable, but hidden faults cause failures in field operation
Solution Approach 1:
The patent implements preliminary anti-action by roughening the optics mounting surface during manufacturing to prevent internal reflections before they can cause transmission failures. This proactive measure eliminates hidden faults that would otherwise manifest as field operation failures, improving reliability while making faults detectable during manufacturing testing.
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 design significantly reduces internal reflections and improves manufacturing yields by ensuring the optical transceivers function effectively at high temperatures, decreasing failure rates from 20-30% to less than 3%.
Implementation Method 1
a base or housing having a roughened and/or darkened optics mounting surface
Implementation Method 2
The dark sealant, coating or adhesive may comprise a polymer resin or epoxy a dark or black pigment, or alternatively, a dark or opaque polymer resin or epoxy. The dark sealant, coating or adhesive may be configured to absorb light having a wavelength of 400-2000 nm
Implementation Method 3
The beam splitter is transparent to one of the outgoing optical signal and the received optical signal and configured to reflect the other of the outgoing optical signal and the received optical signal
Implementation Method 4
The TOSA includes a laser diode configured to convert a received electrical signal to an outgoing optical signal
Implementation Method 5
The ROSA includes a photodiode configured to convert a received optical signal to an outgoing electrical signal
Data Source
AI summary
An optical transceiver and a method of making the same. The optical transceiver includes a base/housing having a roughened or darkened optics mounting surface, a transmitter optical subassembly (TOSA), a receiver optical subassembly (ROSA), a beam splitter mount secured to or mounted on the roughened or darkened optics mounting surface, a beam splitter secured to or mounted on the beam splitter mount, and an optical fiber adapter. The TOSA includes a laser diode configured to convert a received electrical signal to an outgoing optical signal. The ROSA includes a photodiode configured to convert a received optical signal to an outgoing electrical signal. The beam splitter is transparent to one of the outgoing and received optical signals and is configured to reflect the other. The optical fiber adapter is configured to hold an optical fiber that receives the outgoing optical signal and provides the received optical signal.