Optical Fiber Connector Assembly With Encapsulation and Compact Routing
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Solution Overview
Problem
Existing optical connectors in multi-chip optical packages face issues such as incomplete encapsulation leading to reliability concerns, incompatibility with high-volume manufacturing, exposure to mechanical and thermal shock, uncontrolled flow of underfill and encapsulation materials, and large footprint due to fiber shufflers.
Innovation Solution
The solution involves fully encapsulating optical connectors with lids and sealants, using micro channels to control fluid flow, integrating optical fibers in a molded housing, and employing a reduced-footprint fiber shuffler design with a fiber array unit and fiber distribution housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If optical connectors are used to house optical fibers, then optical signal propagation is enabled, but incomplete encapsulation occurs leading to reliability concerns
Solution Approach 1:
The patent merges the optical connector housing with the optics die by directly attaching the ferrule to the optics die surface, eliminating the need for separate encapsulation structures. This integration provides complete encapsulation while maintaining reliability, as the ferrule and optics die form a unified protected assembly.
Solution Approach 2:
The patent employs a nested structure where the ferrule is positioned within a recess on the optics die, and the optical fiber is inserted into the ferrule. This nested arrangement enables complete encapsulation of the optical components while protecting them from environmental factors, thereby improving reliability without adding external complexity.
2Ease of operation
If exposed optical fibers are used, then mechanical flexibility is maintained, but vulnerability to mechanical shock and thermal shock increases
Solution Approach 1:
The patent combines the optical fiber, ferrule, and optics die into a single integrated assembly where the fiber is securely held within the ferrule that is directly attached to the optics die. This merged structure protects the fiber from mechanical shock and thermal shock during handling and solder reflow, while maintaining ease of operation through unified manipulation.
3Ease of operation
If traditional fiber shufflers are used for routing optical fibers, then fiber routing is achieved, but large footprint is required
Solution Approach 1:
The patent extracts the fiber shuffler function from a separate external component and integrates it directly into the optics die. The ferrule is positioned such that optical fibers can be routed directly from the grating coupler on the optics die to the ferrule output, eliminating the need for a large external fiber shuffler and significantly reducing the footprint.
4Reliability
If optical connectors are attached to optics dies, then optical connectivity is established, but compatibility with high volume manufacturing is reduced
Solution Approach 1:
The patent performs preliminary action by pre-attaching the ferrule to the optics die in a controlled manner that facilitates subsequent high-volume manufacturing. The direct attachment method allows for automated assembly processes, and the integrated structure eliminates the need for complex alignment and bonding steps that would reduce manufacturing efficiency.
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3~4A
AI summary
Embodiments disclosed herein include optical connectors for photonic packages. In an embodiment an optical connector comprises a socket and a ferrule inserted into the socket. In an embodiment, the optical connector further comprises a first row of optical fibers in the ferrule, and a second row of optical fibers in the ferrule over the first row. In an embodiment, the optical connector further comprises a fiber distribution housing where the first row of optical fibers and the second row of optical fibers are spread laterally within the fiber distribution housing.