Lens-Array Optical Fiber Connector for Solder Reflow Alignment
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Solution Overview
Problem
Existing mechanical transfer (MT) ferrule technology for optical fiber connections is limited by size constraints and susceptibility to damage during high-temperature solder reflow processes, necessitating a more robust connection approach for optical fiber-to-optical chiplet connectivity.
Innovation Solution
The development of non-physical-contact (NPC) optical fiber connectors using base plates and lens arrays that allow for free-space optical coupling, with materials capable of withstanding high temperatures and maintaining alignment without physical contact, utilizing v-grooves, through-holes, and alignment pins for precise spatial alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical transfer ferrule technology is used for optical fiber connections, then physical connection stability is achieved, but the device is susceptible to damage during high-temperature solder reflow processes and has size constraints
Solution Approach 1:
The patent replaces the mechanical transfer ferrule system with a non-contact optical coupling system using lens arrays. The lens arrays optically couple light between optical fibers without requiring physical contact or mechanical transfer, thereby eliminating the mechanical components that are susceptible to damage during solder reflow processes while maintaining connection stability through precise optical alignment
Solution Approach 2:
The patent introduces lens arrays as intermediary components that mediate the optical coupling between optical fibers. The lens arrays act as non-contact intermediaries that transfer optical signals without requiring direct physical contact between fibers, enabling the system to withstand high-temperature solder reflow processes while maintaining reliable optical connections
2Reliability
If mechanical transfer ferrule technology is used for optical fiber connections, then physical connection is achieved, but size constraints limit the device dimensions
Solution Approach 1:
The patent eliminates the mechanical ferrule structure and replaces it with a compact lens array-based optical coupling system. This substitution reduces the overall device volume while maintaining connection reliability through precise optical alignment and non-contact light transfer, thereby overcoming the size constraints of traditional mechanical transfer technology
3Object-affected harmful factors
If non-physical-contact optical fiber connectors are used, then resistance to high-temperature solder reflow is improved, but alignment precision must be maintained without physical contact
Solution Approach 1:
The patent incorporates alignment pins that perform preliminary alignment of the lens arrays with the optical fibers during assembly. This preliminary mechanical alignment ensures precise optical coupling before the non-contact connection is established, allowing the system to withstand high-temperature solder reflow while maintaining the required alignment precision through the pre-positioned alignment features
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 NPC optical fiber connectors provide reliable and efficient optical fiber connections that withstand high-temperature solder reflow processes, ensuring proper alignment and optical coupling without physical contact, enhancing connectivity in optical data communication systems.
Implementation Method 1
The lens array includes a plurality of lenses respectively aligned with the plurality of v-grooves, such that optical cores of the plurality of optical fibers are respectively optically coupled with the plurality of lenses
Data Source
AI summary
An optical fiber connector assembly includes a base plate, a plurality of optical fibers, a lens array, and a cover plate. A plurality of v-grooves are formed within a top surface of the base plate. The plurality of v-grooves extend from a back side of the base plate to a front side of the base plate. Each of the plurality of v-grooves receives and aligns a corresponding optical fiber. The plurality of optical fibers are respectively disposed within the plurality of v-grooves. The lens array is disposed on the front side of the base plate and includes a plurality of lenses respectively aligned with the plurality of v-grooves, such that optical cores of the plurality of optical fibers are respectively optically coupled with the plurality of lenses. The cover plate is disposed over the plurality of optical fibers within the plurality of v-grooves and is secured to the base plate.