Bidirectional Lattice Ferrule for Waveguide Alignment
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Solution Overview
Problem
Existing multilayer waveguide connectors face challenges in precise alignment and optical communication due to the accumulation of alignment errors and the need for high-quality facet surfaces, which complicates the assembly process and increases manufacturing costs.
Innovation Solution
A ferrule with a bidirectional lattice structure of mechanical alignment slots and an array of lenses for optical communication, combined with a comb-like assembly tool, allows for precise alignment and fixation of waveguide layers, eliminating the need for high-quality facet surfaces and reducing alignment errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional alignment methods are used for multilayer waveguide connectors, then assembly is simpler, but alignment precision deteriorates due to accumulation of alignment errors
Solution Approach 1:
The alignment structure is segmented into multiple independent alignment slots arranged in a bidirectional lattice pattern. Each slot provides independent alignment reference, preventing error accumulation across layers. The waveguide layers are also segmented with individual protrusions that engage with specific slots, enabling precise positioning without relying on cumulative alignment from previous layers.
Solution Approach 2:
Mechanical alignment slots serve as intermediary structures between the ferrule and waveguide layers. These slots provide a mediating alignment mechanism that transfers positional information accurately without direct contact between competing alignment features, thereby maintaining precision while managing structural complexity.
2Reliability
If high-quality facet surfaces are required for optical communication, then optical performance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces mechanical/optical alignment dependence on facet quality with a mechanical alignment system based on protrusions engaging with alignment slots. This substitution allows tolerance for poorer facet surfaces while maintaining alignment precision through the mechanical interlocking mechanism, thereby simplifying facet preparation requirements.
Solution Approach 2:
The alignment slots and protrusions act as intermediary mechanical features that decouple the optical communication quality from direct dependence on facet surface quality. The mechanical alignment interface mediates between the ferrule and waveguides, allowing optical facets to be manufactured with relaxed tolerances while still achieving reliable optical coupling.
3Measurement precision
If traditional single-direction alignment slots are used, then manufacturing is simpler, but alignment precision in multiple directions deteriorates
Solution Approach 1:
The alignment structure transitions from single-direction slots to a bidirectional lattice arrangement, adding a second dimensional aspect to the alignment capability. This bidirectional configuration enables precise positioning in both horizontal and vertical directions simultaneously, achieving 2D alignment precision without requiring complex 3D adjustment mechanisms.
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 solution enables precise alignment of waveguide layers with relaxed thickness control tolerances, scalable to multiple layers, and reduces the number of parts required, improving assembly efficiency and yield while allowing for simpler facet preparation methods.
Implementation Method 1
an array of lenses disposed on a face opposite to the end face, the lenses arranged so as to come in optical communication with cavities of the second slots where the protrusions of the waveguide layers are to be inserted
Data Source
AI summary
A ferrule for a multilayer waveguide connector includes a face having mechanical alignment slots arranged in a bidirectional lattice structure, the mechanical alignment slots including first slots disposed in a first direction, the first slots configured to respectively receive one end of waveguide layers, and second slots disposed in a second direction different from the first direction, the second slots configured to respectively receive protrusions transverse from a main surface of the waveguide layers.