Passive Alignment Connector for Optical Waveguides Using Guide Pins
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Solution Overview
Problem
Current methods for aligning integrated waveguides and optical fibers are challenging, often requiring active alignment, which is costly and time-consuming, and result in inaccuracies due to stacking tolerances, necessitating a more efficient and cost-effective solution.
Innovation Solution
The use of passive alignment systems with guide pins and capture features that engage with a locking mechanism in a connector, allowing for precise alignment of optical fibers with waveguides on a substrate, enabling high-volume processing and reducing coupling loss, while eliminating the need for plastic parts to minimize form factor and ensure high-temperature stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If active alignment is used to align waveguides and optical fibers, then alignment precision is improved, but cost and time consumption increase
Solution Approach 1:
The substrate is pre-formed with precise geometric features (such as grooves, V-grooves, or aligned holes) that automatically guide and position the optical fiber during assembly. This preliminary preparation of alignment features eliminates the need for time-consuming active alignment procedures while maintaining high alignment precision through the pre-engineered geometric constraints.
Solution Approach 2:
The connector design incorporates self-aligning features where the geometric configuration of the substrate features and connector components automatically guides the optical fiber into the correct position without requiring external active alignment systems. The structure itself performs the alignment function through its geometric design, reducing both cost and time.
2Manufacturing precision
If multiple alignment features are used to improve alignment accuracy, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
Multiple alignment functions are merged into a single integrated substrate structure with pre-formed geometric features. Rather than using separate alignment components, the substrate itself incorporates the alignment features (grooves, V-grooves, aligned holes) as an integrated part of its design, reducing overall device complexity while maintaining high manufacturing precision.
Solution Approach 2:
The substrate structure serves multiple functions simultaneously: it provides mechanical support, optical guidance, and precise alignment through its geometric features. This multi-functionality reduces the need for separate dedicated alignment components, thereby reducing device complexity while improving manufacturing precision.
3Ease of manufacture
If plastic parts are used in the connector, then ease of manufacture is improved, but high-temperature stability deteriorates
Solution Approach 1:
The material selection is changed from plastic to metal or ceramic materials that can withstand high temperatures. This parameter change in material composition maintains ease of manufacture through standard fabrication processes while significantly improving high-temperature stability and reliability in harsh environmental conditions.
4Adaptability or versatility
If standardized connectors are used for waveguide interfaces, then adaptability is improved, but manufacturing precision deteriorates due to tolerance stacking
Solution Approach 1:
The connector design incorporates locally optimized geometric features at critical alignment positions that compensate for standardization tolerances. By adding localized precision features (such as tapered grooves, V-grooves with specific angles, or positioned alignment holes) at key locations, the system maintains adaptability through standardization while achieving high manufacturing precision through local geometric optimization that reduces tolerance stacking effects.
Data Source
AI summary
Systems and methods are provided for connection of an optical fiber to a substrate. The substrate may comprise waveguide(s), guide pin(s), and a substrate body. The guide pin(s) define a first and second end and comprise a capture feature proximate the second end. The substrate body comprises a receiving feature configured to receive and connect the first end of guide pin(s), and the second end of guide pin(s) extends outwardly from the substrate body. The system also comprises a connector configured to receive the optical fiber and including a receiver portion that has a locking feature and defines a recess configured to receive the guide pin(s). The capture feature is configured to engage with the locking feature. When the capture feature is engaged with the locking feature, the optical fiber is aligned with the optical waveguide(s) and restrained from movement relative to the substrate.