Optical Coupling Assembly for Self-Aligned PIC Waveguides
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Solution Overview
Problem
The alignment of optical fibers with photonic integrated circuits (PICs) in high-speed optical interconnects is tedious and time-consuming due to dimension variability and fracturing of glass blocks, leading to insertion loss and inefficient communication.
Innovation Solution
The optical coupling device incorporates alignment features such as kinematic features and fiducials on the top and bottom surfaces of the fiber array unit (FAU) to enable self-alignment in the X, Y, and Z directions, allowing for precise alignment with PIC waveguides without manual measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual measurement and alignment methods are used, then alignment can be achieved, but assembly time is excessive and productivity is low
Solution Approach 1:
Alignment features such as V-grooves, ridges, and fiducial markers are pre-formed on the glass blocks during manufacturing. These features automatically establish reference points and geometric constraints that guide the optical fibers and PICs into correct alignment positions during assembly, eliminating the need for time-consuming manual measurements and adjustments
Solution Approach 2:
The alignment features enable the assembly process to be self-aligning. When components are placed on the glass blocks, the pre-formed V-grooves, ridges, and fiducial markers automatically position the optical fibers and PICs in the correct locations without requiring external measurement tools or manual adjustment, significantly reducing assembly time and improving productivity
2Manufacturing precision
If glass blocks are used without alignment features, then manufacturing is simpler, but dimension variability causes misalignment and insertion loss
Solution Approach 1:
Alignment features including V-grooves, ridges, and fiducial markers are incorporated into the glass block structure during the manufacturing process. These features serve as pre-established reference points and geometric constraints that compensate for dimension variability in the glass blocks, ensuring precise alignment of optical components without requiring post-manufacturing adjustments
Solution Approach 2:
The invention changes the geometric parameters of the glass block by adding specific features such as V-grooves with defined angles, ridges with specific heights, and fiducial markers at predetermined locations. These parameter changes create inherent alignment references that guide component positioning, transforming the glass block from a simple support structure into an active alignment tool that compensates for manufacturing tolerances
Data Source
AI summary
An apparatus comprising at least one rigid portion; a plurality of optical channels, wherein a portion of the plurality of optical channels are secured within the at least one rigid portion, the plurality of optical channels comprising first ends extending from the at least one rigid portion; wherein the at least one rigid portion comprises a groove in a surface of the at least one block.