Active Optical Plug for Photonics Package Testing

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Solution Overview

Problem

Legacy optical plug implementations, such as passive loopback connectors, are insufficient for comprehensive testing of photonics packages and can cause damage due to repeated insertion and removal during testing, leading to foreign material accumulation and connector damage.

Innovation Solution

Active optical plugs with integrated photonics chips that generate and detect light signals, electrically couple with the photonics package, and provide native digital and power inputs to test optical and electrical components, while protecting the connectors from dust and debris.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If passive loopback connectors are used for testing, then testing can be performed, but connector damage and foreign material accumulation occur due to repeated insertion and removal

Engineering Contradiction:

Improvetesting efficiencyVSAvoidconnector durability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The active optical plug integrates testing functionality directly into the connector itself, allowing tests to be performed without repeated insertion and removal of external test equipment. The plug remains permanently coupled to the photonics package, enabling multiple tests without compromising connector durability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The active optical plug performs self-testing and testing of the photonics package through integrated photodetectors and light sources. The system tests itself without requiring external test equipment to be repeatedly connected and disconnected, eliminating the mechanical wear associated with traditional testing methods.

Inventive Principle:

Principle #25Self-service

2Measurement precision

If traditional testing methods are used, then optical testing can be performed, but the optical connectors are exposed to dust and physical contact damage

Engineering Contradiction:

Improveoptical testing capabilityVSAvoiddust and debris exposure

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The active optical plug serves as an intermediary device that performs optical testing through integrated photodetectors and light sources within the plug itself. This eliminates the need to expose the photonics package optical connectors to external test equipment, thereby protecting them from dust and physical contact while maintaining full testing capability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If comprehensive optical and electrical testing is required, then multiple test equipment connections are needed, but this increases testing complexity and time

Engineering Contradiction:

Improvetesting comprehensivenessVSAvoidtesting system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The active optical plug combines multiple testing functionalities (optical detection, electrical testing,, and communication) into a single integrated device. This consolidation allows comprehensive optical and electrical testing to be performed through one connection rather than requiring multiple separate test equipment connections, thereby reducing testing complexity and time while maintaining full testing versatility.

Inventive Principle:

Principle #5Merging (Combining)

4Productivity

If repeated insertion and removal of test equipment is performed, then testing can be conducted, but foreign material accumulates in the connector

Engineering Contradiction:

Improvetesting frequencyVSAvoidforeign material accumulation

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The active optical plug is permanently coupled to the photonics package before testing begins, eliminating the need for repeated insertion and removal of test equipment. This preliminary coupling prevents foreign material from entering the connector during frequent connection/disconnection cycles, while still allowing unlimited testing to be performed through the established connection.

Inventive Principle:

Principle #10Preliminary action

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 active optical plugs simplify and enhance the testing of photonics packages by allowing for robust, non-destructive evaluation of optical and electrical functionality, reducing the risk of damage and improving testing efficiency throughout the manufacturing and transit processes.

Implementation Method 1

a photonics chip to generate light to be sent to the photonics package as part of the test protocol

Methodology Applied

Scientific EffectLight emission: Light Emitting Diode

Implementation Method 2

receiving light from the photonics package

Methodology Applied

Scientific EffectLight detection: Photoelectric Effect

Data Source

PatentUS12061230B2Active optical plug to optically or electrically test a photonics package

Publication Date: 2024.08.13 INTEL CORP

AI summary

Embodiments described herein may be related to apparatuses, processes, and techniques related to active optical plugs used to cover optical connectors of a photonics package to protect the connectors. The active optical plugs may also be used to perform testing of the photonics package, including generating light to be sent to the photonics package and to detect light received from the photonics package as part of the test protocol. This allows testing the optical connection and the photonics package, without exposing the optical connections of the package to damage from dust or physical contact. Other embodiments may be described and/or claimed.