Pluggable Expanded Beam Connector for On-Package Optics
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Solution Overview
Problem
The microelectronic industry faces challenges with pigtail type connectors for optical fiber connections, including high fiber alignment defects, non-ideal length issues leading to link loss, and difficulties in high volume manufacturing due to manual handling and alignment complexities.
Innovation Solution
The implementation of pluggable expanded beam connectors with a die side lens and plug side lens for improved alignment tolerances, integrated receptacles with guide pins for easy assembly, and a design that allows for automated and cost-effective assembly processes, reducing manual handling and increasing yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pigtail type connectors with v-grooves are used for optical fiber connections, then optical connections can be established, but fiber alignment defects increase and manufacturing yield decreases
Solution Approach 1:
The optical connection system is segmented into separate components: a fixed v-groove array on the substrate and a movable plug assembly with fibers. This allows the fibers to be aligned and secured in the v-grooves as a unit rather than individually, improving alignment accuracy and reducing manufacturing defects.
Solution Approach 2:
The v-grooves are pre-formed and fixed on the substrate before fiber insertion. This preliminary positioning of the grooves provides a stable reference framework that guides fiber alignment, ensuring consistent alignment accuracy across multiple connections and reducing yield loss.
2Adaptability or versatility
If standard pigtail length is used, then connector compatibility is maintained, but link loss increases due to extra bends and connections
Solution Approach 1:
The plug assembly is designed with flexible positioning capabilities, allowing the fiber length and routing to be dynamically adjusted during assembly. This enables optimization of the optical path to minimize bends and connections, reducing link loss while maintaining compatibility with standard connectors.
3Manufacturing precision
If pigtail and MT ferrules are used for optical connections, then fiber alignment is achieved, but automation for high volume manufacturing becomes challenging due to manual handling requirements
Solution Approach 1:
Multiple fibers are combined into a single plug assembly that is handled as one unit rather than individually. This merging of fibers into a modular assembly enables automated handling and insertion systems, making high-volume manufacturing feasible while maintaining precise alignment through the integrated v-groove structure.
Solution Approach 2:
The plug assembly incorporates self-aligning features such as guide pins and complementary mechanical interfaces that automatically position the fibers correctly in the v-grooves during insertion. This self-alignment mechanism eliminates the need for manual alignment adjustments, enabling full automation of the connection process.
4Quantity of substance
If multiple fibers per die are used to increase bandwidth, then optical connection capacity increases, but alignment complexity and defect risk increase
Solution Approach 1:
The multiple fiber connections are segmented into modular plug assemblies, each containing a subset of fibers organized in a structured array. This segmentation allows each plug to be aligned and secured independently in corresponding v-groove groups, reducing the overall alignment complexity compared to handling all fibers individually while still achieving high connection capacity.
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 solution enhances assembly efficiency, reduces costs, and improves alignment accuracy, leading to higher yields and reduced susceptibility to degradation from dust and debris, while enabling easier integration with high volume manufacturing processes.
Implementation Method 1
expanded beam coupling for on-package optics
Implementation Method 2
optical connections include optical fibers that are mounted to v-grooves on the edge of the photonics die
Data Source
AI summary
Embodiments disclosed herein include photonics packages and systems. In an embodiment, a photonics package comprises a package substrate, where the package substrate comprises a cutout along an edge of the package substrate. In an embodiment, a photonics die is coupled to the package substrate, and the photonics die is positioned adjacent to the cutout. In an embodiment, the photonics package further comprises a receptacle for receiving a pluggable optical connector. In an embodiment, the receptacle is over the cutout.