Optical Assembly Detachable Coupling Alignment
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Solution Overview
Problem
Optical devices face challenges in miniaturization and compact integration with electronic devices due to alignment errors between optical components, which hinders the pace of scaling down and harmonization with electronic devices in co-packaged optics applications.
Innovation Solution
A detachable coupling mechanism is introduced for optical devices and photonic integrated circuits (PICs), utilizing a collimator array with a plug housing and a PIC array with a receptacle housing, featuring a detachable coupling means and lens arrays for precise alignment and reliable light coupling, allowing for compact and high-bandwidth optical assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If optical devices are miniaturized to match electronic device scaling trends, then compact integration in co-packaged optics is improved, but alignment precision between optical components deteriorates
Solution Approach 1:
The optical device is divided into separate functional modules: a collimator array module and a lens array module, each housed in its own housing. This segmentation allows independent optimization of alignment mechanisms for each module, enabling compact overall size while maintaining precise alignment through modular assembly features.
Solution Approach 2:
A detachable coupling mechanism serves as an intermediary between the collimator array module and lens array module. This coupling includes alignment features such as guide pins and positioning structures that mediate the connection, ensuring precise alignment between optical components while allowing for compact integration of the overall device.
2Ease of manufacture
If alignment tolerance between optical components is increased to facilitate assembly, then ease of manufacture is improved, but light coupling efficiency deteriorates
Solution Approach 1:
The housing structures incorporate pre-formed alignment features such as guide pins, positioning slots, and interlocking geometries that automatically establish correct relative positions between optical modules during assembly. This preliminary action of pre-positioning ensures high alignment precision is achieved without requiring complex manual adjustment procedures.
Solution Approach 2:
The design replaces complex mechanical adjustment mechanisms with precision-machined alignment features integrated into the housing structures. Instead of using adjustable mounts or manual positioning systems, the patent employs fixed geometric alignment features that provide both ease of assembly and high coupling efficiency through precise mechanical interfitting.
3Ease of operation
If a detachable coupling mechanism is introduced to enable easy assembly and disassembly, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The detachable coupling mechanism is merged with the housing structures themselves, rather than being a separate component. The alignment features and coupling elements are integrated into the collimator array housing and lens array housing, combining the functions of structural support, alignment, and detachable connection into unified components.
Solution Approach 2:
The housing structures serve multiple functions: they provide structural support for optical components, incorporate alignment features for precise positioning, and include detachable coupling elements for easy assembly and disassembly. This multi-functionality reduces the need for separate dedicated components, thereby reducing overall device complexity despite the added capability of detachability.
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
The solution enables a compact and reliable optical assembly with increased alignment tolerance, supporting high-bandwidth applications and rapid data growth by ensuring precise and efficient light coupling between optical and PIC components, while allowing for easy assembly and disassembly.
Implementation Method 1
Each collimator lens is optically coupled to a corresponding fiber core and configured to receive light from the fiber core and transform the light into a collimated light beam
Implementation Method 2
The PIC lens array is fixated to the PIC and separated from the PIC by a first adhesive, and optically coupled to the waveguides
Data Source
AI summary
The present disclosure provides an optical device including a collimator array, a plug housing, and a detachable coupling means. The collimator array includes a fiber array and a collimator lens array. The fiber array includes fibers, a plate holder, and a groove. The plate holder carries the fibers. The groove is on a top face of the plate holder and parallel along a longitudinal direction of the fibers. The plug housing is fixated to the collimator array in part by engagement of a strip protrusion at a bottom face of the plug housing to the groove on the top face of the plate holder. The detachable coupling means is at a side surface of the plug housing and configured to mechanically couple the plug housing to a corresponding receptacle housing external to the optical device.