Oblique Angle Optical Fiber Assembly for High Density Photonic Integration
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Solution Overview
Problem
Current photonic chip technologies face challenges in efficiently and scalably bringing light onto and extracting it from photonic circuits, particularly in mass production settings involving hundreds of optical fibers, with existing solutions like grating couplers having limited fiber density due to large mounting blocks and lacking detailed manufacturing means.
Innovation Solution
The design and construction of an optical fiber sub-assembly using grating optical mode transformers with a support plate and alignment template plate, featuring tilted and flared holes, compliant films, and spacers, allowing for precise alignment and efficient light exchange between optical fibers and silicon waveguides, enabling scalable integration with photonic circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If grating couplers are used to couple light between optical fibers and photonic circuits, then light coupling is enabled, but fiber density is limited due to large mounting blocks
Solution Approach 1:
The mounting block is segmented into multiple smaller blocks, each containing a subset of optical fibers. This segmentation allows for higher fiber density while maintaining the functionality of grating couplers for light coupling between optical fibers and photonic circuits.
Solution Approach 2:
The patent transitions from a two-dimensional array of fibers to a three-dimensional arrangement by stacking multiple layers of fiber arrays vertically. This dimensional change enables significantly higher fiber density without increasing the horizontal footprint of the mounting block.
2Manufacturing precision
If precise alignment between optical fibers and photonic circuits is achieved, then light coupling efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
Alignment features such as V-grooves, through-holes, and fiducial markers are pre-formed in the mounting block during manufacturing. Optical fibers are pre-positioned in these features before final assembly with the photonic circuit, enabling precise alignment without complex real-time adjustment mechanisms.
Solution Approach 2:
The mounting block serves as an intermediary component that provides a rigid, pre-structured platform for holding and positioning optical fibers. This intermediary structure mediates between the optical fibers and photonic circuits, simplifying the overall assembly process while maintaining alignment precision through its integrated alignment features.
3Quantity of substance
If a large number of optical fibers are integrated with photonic circuits, then optical I/O capacity is enhanced, but light loss increases
Solution Approach 1:
The mounting block provides individualized support and positioning for each optical fiber through dedicated V-grooves and through-holes. This localized structural quality ensures optimal alignment and minimal bending for each fiber, reducing insertion loss and maintaining high coupling efficiency even as the total number of fibers increases.
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 reduces light loss to acceptable levels and facilitates the efficient exchange of light between a large number of optical fibers and photonic circuits, addressing the scalability and precision issues in existing technologies by enabling precise alignment and efficient coupling.
Implementation Method 1
efficient transition of light between the two sets of light guides is affected by means of an optical mode transformer... periodic and semi periodic structure that comprises the optical mode transformer
Data Source
AI summary
An optical fiber assembly and a method of assembly thereof. The optical fiber assembly includes a support plate defining an array of support plate through holes, and an alignment template plate defining an array of alignment template plate through holes. At least one support plate through hole or alignment template plate through hole may be flared. At least one support plate through hole or alignment template plate through hole may include a compliant film.