Adiabatic Optical Core Coupling With Wider Alignment Tolerance
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Solution Overview
Problem
There is a demand for improving the connection reliability between the first optical component and the second optical component in optical modules, particularly in terms of maintaining consistent optical coupling despite misalignment during manufacturing or assembly.
Innovation Solution
The optical module design includes a first optical component with a single core optically coupled to multiple second cores via adiabatic coupling, separated by a separator in a specific direction, with the cores arranged orthogonally and overlapping in another direction, ensuring a greater separation distance between adjacent second cores than the first core, thereby allowing for wider tolerances in alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the first core and multiple second cores are arranged close together to improve optical coupling efficiency, then coupling loss decreases, but manufacturing alignment precision requirements increase
Solution Approach 1:
The patent transitions from a two-dimensional planar arrangement to a three-dimensional stacked configuration, with the first core and multiple second cores positioned at different vertical levels separated by a separator. This dimensional change enables sufficient horizontal separation distance while maintaining effective optical coupling through vertical overlapping, thereby reducing both coupling loss and alignment precision requirements.
Solution Approach 2:
A separator is introduced as an intermediary component between the first core and the multiple second cores. This separator provides both physical separation to prevent unwanted optical interference and structural support for maintaining precise spatial relationships, enabling reliable optical coupling without requiring extremely tight manufacturing tolerances.
2Ease of manufacture
If the separation distance between the first core and multiple second cores is increased to simplify manufacturing, then alignment tolerance improves, but optical coupling efficiency decreases
Solution Approach 1:
By utilizing the vertical dimension with the separator, the patent achieves effective optical coupling without requiring small horizontal separation distances. The cores can be positioned with relaxed alignment tolerance while maintaining sufficient overlapping in the vertical direction to ensure efficient optical coupling.
3Device complexity
If multiple second cores are arranged side by side in the same plane as the first core, then optical coupling is simplified, but manufacturing alignment difficulty increases
Solution Approach 1:
The patent arranges the multiple second cores side by side in the horizontal direction while positioning them at a different vertical level from the first core, separated by a separator. This three-dimensional arrangement simplifies the optical coupling structure by maintaining side-by-side configuration while eliminating the need for precise planar alignment through the vertical separation provided by the separator.
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 effectively limits coupling loss even with misalignment, enhancing manufacturing yield and reliability by allowing a broader range of positional displacement without significant loss in optical coupling efficiency.
Implementation Method 1
The second optical component includes multiple second cores optically coupled to the single first core by adiabatic coupling
Data Source
AI summary
An optical module includes a first optical component having a single first core, a second optical component having multiple second cores optically coupled to the first core by adiabatic coupling, and a separator separating the first core from the second cores in a first direction. The first core and the second cores are arranged to allow optical coupling from the first core to the second cores. The second cores are arranged side by side in a second direction that is orthogonal to the first direction. The first core overlaps the second cores in an overlapping region in a third direction that is orthogonal to both the first direction and the second direction. A first separation distance between two adjacent ones of the second cores in the second direction is greater than or equal to a second separation distance between the first core and the second cores in the first direction.