Optical Interconnect Alignment Using Dummy Core and Lens
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Solution Overview
Problem
Current micro-lens connector assembly processes on polymer waveguide substrates face reliability issues and low contrast during mass production due to protruding alignment markers, which hinder precise alignment and increase insertion loss in optical interconnect structures.
Innovation Solution
The implementation of dummy cores, dummy lenses, and dummy mirrors on the waveguide substrate allows for precise alignment of the micro-lens connector using inspection light, enabling automatic camera inspection and improving the coupling efficiency between waveguide and fiber sides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If protruding alignment markers are used for manual assembly, then alignment can be achieved, but reliability issues occur during mass production and contrast is low for automatic inspection
Solution Approach 1:
The patent uses dummy cores and dummy lenses as copies of the actual optical components. These dummy structures serve as alignment markers that can be detected by automatic inspection systems without the reliability issues of protruding markers. The dummy core is positioned at a known location relative to the waveguide core, and the dummy lens is positioned relative to the actual lens array, creating a reproducible alignment reference system
Solution Approach 2:
The patent replaces the mechanical protruding alignment markers with an optical alignment system using dummy cores and dummy lenses. Instead of relying on physical contact markers that cause reliability issues, the system uses optical paths and light transmission through the dummy structures to achieve alignment, which can be detected by automatic camera inspection systems
2Manufacturing precision
If protruding alignment markers are used, then alignment can be achieved, but contrast is low when viewed by automatic camera inspection system
Solution Approach 1:
The dummy core and dummy lens create optical copies or representations of the actual optical path. The dummy core is positioned to correspond with the waveguide core location, and the dummy lens corresponds to the actual lens position. This creates high-contrast optical features that can be easily detected by automatic inspection cameras, replacing the low-contrast protruding markers
3Productivity
If dummy core and dummy lens alignment method is used, then mass production yield is enhanced, but device complexity increases
Solution Approach 1:
The patent divides the alignment function into separate segments: the dummy core on the waveguide substrate and the dummy lens on the lens array substrate. This segmentation allows each component to be manufactured and aligned independently, then bonded together. The segmentation enables automated alignment processes to work on each substrate separately, improving mass production yield while managing complexity through modular design
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 method enhances the mass production yield of optical interconnect structures by ensuring precise alignment, reducing insertion loss, and improving the reliability of micro-lens connector assembly, thereby increasing the quality and bandwidth of optical communication systems.
Implementation Method 1
injecting inspection light into the dummy core to reach the dummy mirror
Implementation Method 2
inspection light from the inspection opening... reach the dummy mirror
Data Source
AI summary
An optical interconnect structure includes a lens array and a waveguide substrate. The lens array has a dummy lens. The waveguide substrate has a dummy core, a dummy mirror corresponding to the dummy core, and an inspection opening for injecting inspection light into the dummy core to reach the dummy mirror. In the optical interconnect structure, the lens array is mounted on the waveguide substrate such that the dummy lens of the lens array is positioned on the dummy mirror by monitoring inspection light from the inspection opening.