Co-Packaged Optical Connector Alignment Without Guide Pins
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Solution Overview
Problem
Conventional optical connectors for Co-Packaged Optics (CPO) applications require customization and brute-force alignment, limiting material selection and flexibility, and often necessitate guide pins that restrict component choices.
Innovation Solution
The optical system includes an optical engine with coarse and fine alignment features, such as chamfered edges and radiused corners, to facilitate alignment without guide pins, allowing the use of materials like glass or silicon, and a backfill material for mechanical support, enabling compact interfaces and reduced mating forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional optical connectors are used for CPO applications, then connection can be established, but customization is required and material selection is limited due to guide pins
Solution Approach 1:
The patent removes guide pins from the optical connector design. By extracting this alignment component, the system eliminates the material selection limitations that guide pins impose on optical engine components, allowing greater freedom in material choices while maintaining connection functionality through alternative alignment mechanisms
Solution Approach 2:
The optical connector is designed to work with universal optical engine interfaces without requiring customization. The connector achieves compatibility across different material compositions through its guide pin-free design, enabling a single connector type to interface with various optical engine configurations
2Manufacturing precision
If guide pins are used for alignment, then connection alignment is achieved, but material selection of optical engine components is limited
Solution Approach 1:
Guide pins are completely removed from the connector design. The alignment function previously performed by guide pins is replaced by alternative mechanisms that do not constrain material selection, thereby achieving both alignment precision and material freedom
Solution Approach 2:
The mechanical alignment system using guide pins is replaced with a different alignment approach that uses optical or geometric features rather than physical guide pins, allowing optical engine components to be made from various materials including glass without being constrained by guide pin requirements
3Reliability
If conventional optical connectors are used, then connection is established, but brute-force application is required
Solution Approach 1:
The optical connector incorporates self-aligning features that automatically guide the connector into proper alignment with the optical engine during mating. This self-alignment mechanism eliminates the need for brute-force application, reducing mating force while ensuring reliable connection through automatic positioning
4Adaptability or versatility
If customized connectors are used, then specific application requirements are met, but device complexity increases
Solution Approach 1:
A single universal optical connector design is created that can satisfy multiple application requirements without requiring customization. The connector achieves broad applicability through its guide pin-free design and self-aligning features, eliminating the need for multiple specialized connector variants
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 flexible optical connector use, reduces the need for customized components, and enhances alignment precision while supporting thermal expansion mismatch, resulting in lower coupling losses and maintenance.
Implementation Method 1
an optical lens array, the optical lens array has a lens that is optically aligned with a waveguide in the PIC. The optical system also includes an optical connector optically aligned with the optical lens array to transfer optical signals between the optical connector and the waveguide in the PIC
Data Source
AI summary
An optical system is provided. The optical system includes an optical engine having a photonic integrated circuit (PIC) and an optical lens array, the optical lens array has a lens that is optically aligned with a waveguide in the PIC. The optical system also includes an optical connector optically aligned with the optical lens array to transfer optical signals between the optical connector and the waveguide in the PIC. The optical connector includes a ferrule and an optical fiber mated with the ferrule. The ferrule has a lens aligned with the lens of the optical lens array.