Fiber Array Unit Mesa Slot Design for Optical Fiber Strain Relief

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Solution Overview

Problem

Current fiber array unit (FAU) configurations are prone to optical fiber cracking due to bending during fiber routing and reliability testing, as they fail to adequately control fiber strain, leading to common failure modes in photonics systems.

Innovation Solution

The introduction of a second mesa with a slot in the FAU design, which confines the optical fiber and reduces bending, combined with a soft epoxy to absorb strain, and an extended epoxy cone to further minimize stress on the fiber.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a traditional FAU design with a single mesa and v-groove is used, then the structure is simple, but the optical fiber is prone to cracking due to bending during routing and testing

Engineering Contradiction:

ImproveFAU structureVSAvoidoptical fiber reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The single mesa structure is divided into two separate mesas: a first mesa containing the v-groove for fiber reception and a second mesa containing the slot for fiber confinement. This segmentation allows each mesa to perform a specific function, reducing overall fiber stress while maintaining structural simplicity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A soft epoxy material is introduced as an intermediary between the optical fiber and the rigid FAU structure. This epoxy absorbs strain and stress, protecting the fiber from cracking during routing and reliability testing while maintaining the fiber's positional stability

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If soft epoxy and external support designs are used to relieve strain, then some strain protection is provided, but fiber bending is not sufficiently controlled during routing and handling

Engineering Contradiction:

Improvefiber strain reliefVSAvoidfiber routing control

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The FAU structure implements different local qualities by creating a v-groove in the first mesa with specific geometric properties for fiber reception, and a slot in the second mesa with different properties for fiber confinement. Each region is optimized for its specific function, providing both strain relief and routing control

Inventive Principle:

Principle #3Local quality

3Ease of operation

If the fiber is allowed to extend freely over the recessed surface, then the routing is easy, but the fiber gets stressed during reliability testing leading to cracking

Engineering Contradiction:

Improvefiber routingVSAvoidfiber stress resistance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The optical fiber is pre-positioned and confined within the slot of the second mesa before reliability testing occurs. This preliminary confinement action prevents the fiber from experiencing excessive stress during subsequent testing operations, thereby improving reliability while maintaining ease of initial routing

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20240069287A1Novel design for fiber array unit (FAU) for optical transceiver products

Publication Date: 2024.02.29 INTEL CORP

AI summary

A fiber array unit (200) and a photonics system (890), a fiber array unit (200) comprises a substrate (205) with a first el end and a second end. A first mesa (207) is adjacent to the first end and a second mesa (209) is adjacent to the second end. A v-groove (211) is in the first mesa (207) and a slot (213) is in the second mesa (209). The v-groove (211) is aligned with the slot (213).