Modular Interposer for Optical Coupling with Perpendicular Axes
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Solution Overview
Problem
The complexity of manufacturing active cable assemblies is increased by compound optical couplings in traditional interposers, which require precise alignment of multiple optical components, making the process difficult and prone to errors.
Innovation Solution
A modular interposer design with separate and discrete components for lenses and fibers, allowing for passive alignment and simplified manufacturing by segregating optical couplings, enabling independent testing and inspection of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional interposer design with compound optical couplings is used, then optical coupling between OEDs and fibers is achieved, but manufacturing complexity increases exponentially due to multiple precise alignments required
Solution Approach 1:
The interposer is divided into separate discrete components: a lens component and a fiber component. This segmentation eliminates the need for compound optical couplings within a single component, reducing manufacturing complexity while maintaining optical coupling functionality through modular assembly of the separated components.
2Reliability
If traditional integrated interposer design is used, then optical coupling is achieved, but inspection and testing of individual components becomes difficult
Solution Approach 1:
By separating the interposer into distinct lens and fiber components, each component can be independently inspected and tested for defects, alignment accuracy, and optical performance. This modular structure enables targeted quality control measures without requiring inspection of the entire integrated assembly.
3Manufacturing precision
If compound optical couplings are used in single component, then optical coupling is achieved, but alignment precision requirements increase exponentially
Solution Approach 1:
The optical coupling path is divided into separate stages: OED-to-lens coupling and lens-to-fiber coupling. Each stage can be optimized and aligned independently, reducing the cumulative alignment complexity that would arise from attempting to achieve compound couplings within a single component.
4Ease of manufacture
If modular discrete components are used, then manufacturing is simplified and inspectability is enhanced, but additional component interfaces are introduced
Solution Approach 1:
The lens component serves as an intermediary element between the OEDs and the fiber component. This mediator enables simplified manufacturing and independent inspection of discrete components while managing the interface complexity through a standardized optical coupling mechanism that balances modularity benefits with interface control.
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 modular design simplifies manufacturing, enhances inspectability, and improves performance by reducing susceptibility to misalignments and dust, while allowing for robust adhesive bonding and easier assembly.
Implementation Method 1
The reflective surface 1209 turns the light at 90 degrees between the lenses 1204 and the fiber 1210
Implementation Method 2
The lenses 1204 are defined by an air space 1211 between the lens surface and the glass plate
Data Source
AI summary
An interposer for optically coupling an optical device (OD) to a fiber, the OD mounted on a substrate, the interposer comprising: (a) a lens component comprising at least one lens for optically coupling with the OD the lens having a first optical axis, a first surface for mating with the substrate, and a second surface for mating with a third surface of a fiber component; (b) the fiber component comprising the third surface and a cavity for receiving at least one fiber and holding the fiber along a second optical axis, the first and second optical axes being perpendicular; and (c) wherein at least one of the lens component or the fiber component comprises a reflective surface for optically coupling the lens to a point along the second optical axis and adjacent the cavity.