Optical Interposer Waveguide Splitting for Welded Fiber PIC Links
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Solution Overview
Problem
Conventional optical connections in high bandwidth and high powered optical communication systems face issues with adhesive attachments that are inadequate for high power density connections, leading to signal degradation, misalignments, and increased costs and potential failure points.
Innovation Solution
The use of optical interposers with welded optical fibers and embedded waveguides that support a substrate to distribute high-powered optical signals to multiple photonic integrated circuits (PICs), reducing misalignments and providing redundancy through directional couplers and optical redistribution elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple optical signal sources are used for high-powered optical connections, then signal transmission integrity is improved, but system cost and power usage increase
Solution Approach 1:
The patent merges multiple optical signal paths into a single high-powered optical fiber by combining multiple lasers into one fiber, then using an optical interposer with waveguide networks and redistribution elements to split the signal to multiple PICs. This reduces the number of optical fibers and connections needed, lowering cost and power usage while maintaining signal integrity through the interposer's optical redistribution capability.
2Ease of manufacture
If adhesive attachments are used for optical connections, then assembly is simplified, but reliability and power tolerance deteriorate
Solution Approach 1:
The patent replaces adhesive attachments with welded mechanical connections between the optical interposer substrate and the optical fibers/PICs. This welded connection provides superior mechanical strength, thermal conductivity, and power tolerance compared to adhesives, while maintaining assembly feasibility through standardized welding processes.
3Ease of manufacture
If conventional optical connections are used, then implementation is straightforward, but fiber alignment tolerances are stringent
Solution Approach 1:
The optical interposer serves as an intermediary component between the optical fiber and the PICs, providing a standardized interface with integrated waveguide networks and redistribution elements. This intermediary structure relaxes fiber alignment tolerances by incorporating alignment features and compensation mechanisms within the interposer, making the connection process more forgiving and easier to manufacture.
4Use of energy by moving object
If a single high-power laser source is used with optical redistribution, then cost and power usage are reduced, but signal distribution complexity increases
Solution Approach 1:
The optical interposer segments the optical signal distribution function into distinct components: the waveguide network for signal routing, the redistribution elements for signal splitting, and the interface structures for connection. This segmentation organizes the complexity into manageable, standardized modules that can be manufactured and assembled systematically, reducing overall system complexity despite the sophisticated signal distribution capability.
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
Enhances signal integrity and reduces costs by allowing efficient redistribution of high-powered optical signals to multiple PICs, while offering increased tolerance to optical power and compatibility with reflow assembly methods, and minimizing alignment issues.
Implementation Method 1
an optical waveguide network may be defined by the substrate
Implementation Method 2
the plurality of optical redistribution elements may successively split the first input optical signal such that a plurality of output optical signals is directed to the plurality of PICs
Implementation Method 3
a first end that receives a first optical fiber welded thereto
Data Source
AI summary
Apparatuses, systems, and associated methods of manufacturing are described that provide an optical interposer and associated communication system. An example optical interposer includes a substrate having a first end that receives a first optical fiber welded thereto and a second end that receives a plurality of photonic integrated circuits (PICs) attached thereto. The interposer further includes an optical waveguide network defined by the substrate that provides optical communication between the first welded optical fiber and the plurality of PICs. The optical waveguide network also includes optical redistribution elements supported by the substrate. In an operational configuration, the optical interposer receives a first input optical signal from the first welded optical fiber, and the plurality of optical redistribution elements successively split the first input optical signal such that a plurality of output optical signals is directed to the plurality of PICs.