Lensed Substrate Optical Connectors for Low-Loss Assembly
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Solution Overview
Problem
Current optical connectors face challenges in achieving low loss and high reliability, especially in high-density applications, due to mechanical force requirements and difficulties in automating the assembly process, particularly for multi-fiber connectors and polarization maintaining fibers.
Innovation Solution
The development of optical components with a lens substrate and an array of lenses, where optical fibers are bonded to the substrate, allowing for active alignment and laser bonding to achieve precise alignment and low optical loss, independent of fiber geometry, and the use of a ferrule with a substrate slot and fiber channel for secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polymer injection molded ferrule is used for lensed connectors, then manufacturing is simplified, but reliability for high-power applications deteriorates
Solution Approach 1:
The patent replaces the polymer injection molded ferrule with a ceramic ferrule and substrate assembly. The ceramic ferrule provides mechanical support and positioning, while the substrate with integrated lenses provides optical functionality. This substitution of materials (from polymer to ceramic) resolves the contradiction by providing both manufacturability and high-power reliability.
Solution Approach 2:
The patent divides the connector into separate functional components: a ferrule for mechanical support, a substrate for optical lenses, and fiber alignment features. This segmentation allows each component to be optimized independently - the ferrule for mechanical reliability and the substrate for optical performance - thereby resolving the contradiction between ease of manufacture and reliability.
2Manufacturing precision
If active alignment and laser bonding are used, then alignment precision is improved, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates self-aligning features directly into the substrate and ferrule design, such as alignment pins, grooves, and geometric constraints. These features automatically guide the fiber and lens into proper alignment during assembly, reducing or eliminating the need for complex active alignment processes while maintaining high precision.
Solution Approach 2:
The patent pre-configures the substrate with precisely positioned lenses and the ferrule with alignment features before final assembly. This preliminary preparation of alignment features allows for simpler, more repeatable bonding processes while achieving high alignment precision, thereby resolving the contradiction between precision and complexity.
3Reliability
If fiber orientation is controlled for polarization maintaining fibers, then optical performance is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent employs asymmetric design features in the ferrule and substrate that correspond to the asymmetric stress application required for polarization-maintaining fibers. The asymmetric geometry provides mechanical stress that maintains the polarization state, eliminating the need for complex fiber orientation control during assembly while preserving optical performance.
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 enables the creation of low-loss optical connectors with improved reliability and ease of assembly, capable of handling multiple optical channels with reduced mechanical force and increased precision, thereby addressing the limitations of existing connectors.
Implementation Method 1
an optical beam has an expanded beam diameter that is less than 100 μm at a surface of each lens of the array of lenses
Implementation Method 2
propagating an optical signal through the at least one optical fiber and into the substrate
Data Source
AI summary
Optical components and optical connectors for optical communication are disclosed. In one embodiment, an optical component includes a substrate having a lens surface, a fiber coupling surface, and an array of lenses at the lens surface. The optical component further includes an array of optical fibers bonded to the fiber coupling surface such that the array of optical fibers is aligned with the array of lenses in a plane defined by the fiber coupling surface.