Optical Connector Assembly for Chip Waveguide Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The alignment of optical waveguides in silicon-based photonic devices with optical fibers requires expensive and time-consuming active alignment processes, and existing optical connector assemblies struggle to accommodate the small pitch and varying configurations of optical waveguides, making detachable and efficient optical connections challenging.
Innovation Solution
The development of an optical connector assembly featuring a ferrule with bores and a waveguide support that allows for detachable connections, including edge, surface, or evanescent coupling, with a chip coupling surface that matches the optical chip's waveguide configuration, enabling repeatable mating and demating of optical connectors and accommodating different waveguide pitches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If active alignment process is used to align optical waveguides with optical fibers, then alignment precision is improved, but manufacturing cost and time consumption increase significantly
Solution Approach 1:
The patent implements preliminary action by pre-aligning optical waveguides to optical fibers during the manufacturing process and permanently affixing them before final assembly. This preliminary alignment and fixation eliminates the need for time-consuming active alignment during final assembly, thereby improving throughput while maintaining alignment precision.
Solution Approach 2:
The patent uses passive alignment methods that rely on precise mechanical copying of alignment features between the optical chip and fiber connector components. By copying alignment geometries through precision machining and fixture design, the system achieves high alignment precision without requiring expensive active alignment equipment or processes.
2Reliability
If optical fibers are permanently affixed to the optical chip, then connection reliability is improved, but adaptability and ease of repair deteriorate
Solution Approach 1:
The patent segments the optical connection system into three distinct parts: the optical chip with waveguides, the optical connector assembly with fibers, and the mounting structure. This segmentation allows the optical connector assembly to be permanently affixed to the optical chip (ensuring reliability) while still enabling the entire assembly to be detached and replaced if needed (maintaining adaptability).
Solution Approach 2:
The patent creates a hierarchical structure where permanent bonding occurs at the chip-connector interface (static, reliable connection) while the overall assembly remains dynamically replaceable (detachable for repair or reconfiguration). This dynamic-static hierarchy resolves the contradiction between reliability and adaptability.
3Manufacturing precision
If optical connector assembly is designed to accommodate small pitch waveguides, then manufacturing precision for waveguide coupling is improved, but device complexity increases
Solution Approach 1:
The patent introduces an intermediary optical connector assembly that bridges the optical chip with small pitch waveguides and standard optical fibers. This intermediary component absorbs the complexity of precise small pitch coupling through its internal design (ferrule with precisely positioned fiber receptacles) while presenting a simple, standard interface to the external system, thereby reducing overall device complexity.
Solution Approach 2:
The patent changes the spatial parameters within the connector assembly by using precise ferrule positioning and fiber receptacle spacing to transform small pitch waveguide spacing into standard pitch fiber spacing. This parameter transformation enables high precision coupling without requiring the entire system to be redesigned for small pitch configurations.
4Ease of manufacture
If standard configuration optical fibers are used in optical connector assembly, then ease of manufacture and availability are improved, but adaptability to different waveguide configurations deteriorates
Solution Approach 1:
The patent uses parameter changes within the connector assembly design, specifically varying the positioning and orientation of fiber receptacles in the ferrule to accommodate different waveguide configurations. This allows the use of standard optical fibers while adapting to different pitch and configuration requirements through geometric transformation in the connector.
Solution Approach 2:
The patent designs the optical connector assembly with universal features that can accommodate multiple waveguide configurations. By incorporating adjustable or multi-position fiber receptacles and flexible alignment mechanisms, the connector can work with different waveguide pitches and configurations while maintaining ease of manufacture using standard fibers.
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 allows for efficient, repeatable, and cost-effective optical connections with reduced alignment issues and thermal expansion mismatch, enabling testing before final assembly and withstanding solder reflow processes, while maintaining low insertion loss.
Implementation Method 1
optical signals are propagated through an optical chip within optical waveguides
Data Source
Figure 1A
Figure 1B~2
Figure 3~4
AI summary
Detachable optical connectors for optical chips and methods of their fabrication are disclosed. In one embodiment, an optical connector includes a ferrule that supports ferrule waveguides. The optical connector further includes a waveguide support coupled to the ferrule and that supports transition waveguides that are optically coupled to the ferrule waveguides. Ends of the ferrule waveguides are exposed at one end of the ferrule to define a first pitch while ends of the second waveguides are exposed at a chip coupling surface of the waveguide support. The transition waveguides provide at least one type of transition for the guided light traveling within the ferrule waveguides to enable either edge coupling, surface coupling or evanescent coupling to chip waveguides of an optical chip. The transition can include a change in mode-field diameter, direction of the guided light, and/or pitch.