Elastic Averaging Coupling for Optical Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for coupling optical fibers to photonic integrated circuits (PICs) face challenges due to size mismatch, requiring stringent alignment tolerances and are costly, with existing connectors being elastically compliant and thermally unstable, leading to misalignment and high costs.
Innovation Solution
A demountable passive alignment coupling using elastic averaging alignment features, comprising complementary arrays of protrusions on two bodies that intermesh for precise alignment, allowing for non-destructive and repeatable optical connection and disconnection, maintaining alignment accuracy and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If polymer connector components are used to achieve stringent alignment tolerances, then alignment precision is improved, but the connectors become elastically compliant and deform under external loads, reducing reliability
Solution Approach 1:
The patent changes the material parameter from polymer to metal, fundamentally altering the mechanical properties. The metal base material provides dimensional stability and resistance to elastic deformation under load, while still enabling precise alignment through the elastic averaging mechanism of the protrusion array.
Solution Approach 2:
The patent employs a composite structure combining metal base material with an elastic averaging coupling mechanism. The metal provides structural stability while the elastic averaging protrusion array provides precise alignment, creating a composite system that achieves both reliability and precision.
2Manufacturing precision
If polymer connector components are used for alignment, then alignment precision is improved, but thermal expansion causes misalignment and mechanical stress at elevated temperatures, reducing reliability
Solution Approach 1:
The patent changes the material parameter from polymer to metal, which has superior thermal stability. The metal base material exhibits lower thermal expansion coefficients and maintains dimensional stability at elevated temperatures, preventing thermal misalignment and mechanical stress while preserving alignment precision.
3Manufacturing precision
If active alignment approach is used to align optical fiber arrays to PIC elements, then alignment precision is improved, but the process becomes time-consuming and postpones fiber-optic connection to the end of production, reducing productivity
Solution Approach 1:
The patent implements self-aligning features where the protrusion arrays automatically guide and position the optical fiber array relative to the PIC elements. This self-service alignment mechanism eliminates the need for time-consuming active alignment procedures while maintaining high alignment accuracy through the geometric precision of the protrusion array.
4Reliability
If permanent attachment of optical fiber array to PIC is made, then connection reliability is improved, but the connection becomes non-demountable and destructive, eliminating adaptability
Solution Approach 1:
The patent transforms the static permanent attachment into a dynamic demountable connection. The elastic averaging coupling mechanism allows the optical fiber array to be securely attached during operation for reliable light transmission, while enabling controlled detachment when adaptability or reconfiguration is needed, thus providing both reliability and versatility.
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 achieves high alignment accuracy and repeatability, reduces manufacturing costs, and prevents thermal misalignment, enabling efficient and cost-effective optical coupling of optical fibers to PICs while maintaining optical alignment during connect, disconnect, and reconnect cycles.
Implementation Method 1
When the first body is pressed against the second body with the first and second arrays of alignment features mating towards each other, the first and second arrays of protrusions intermesh
Data Source
AI summary
A passive optical alignment coupling between two bodies each having a complementary interstitial two-dimensional planar array of protrusions defining an array of interstices. Each array of protrusions defines an array of discrete protrusions separated and isolated from one another on the surface of the corresponding bodies. When the bodies are pressed together, the array of protrusions defined on one body intermesh with protrusions defined on the other body with protrusions of one body received in corresponding interstices defined on the other body. The protrusion surfaces of each adjacent pair of protrusions are in point contact. The first body is removably attachable to the second body to define a demountable coupling, with the first array of alignment features against the second array of alignment features to define an elastic averaging coupling, thereby passively aligning the first body to the second body.