Polymer Lens Array Optical Coupling for Silicon Photonics
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Solution Overview
Problem
Existing optical coupling systems for silicon photonics face challenges in alignment accuracy and speed due to the need for active alignment of fiber blocks and the use of adhesives, which can lead to increased optical loss and occupy valuable board space, especially as operational speeds increase and the distance between optical transceivers and electronic systems needs to be minimized.
Innovation Solution
An optical coupling system with a body and an array of lenses integrally formed with polymer material, where the lenses are directly formed on the silicon photonics integrated circuit using wafer-level fabrication, eliminating the need for adhesives and enabling precise alignment, thus reducing optical loss and footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If active alignment of fiber block to silicon photonics is used, then coupling accuracy is improved, but manufacturing time and complexity increase
Solution Approach 1:
The patent applies preliminary action by pre-forming lens arrays directly on the silicon photonics chip during wafer-level fabrication before final assembly. This pre-positioning of lenses eliminates the need for time-consuming active alignment of fiber blocks during manufacturing, as the lenses are already precisely positioned to match the grating couplers.
Solution Approach 2:
The patent replaces the mechanical active alignment system with a lithographically defined lens array system. Instead of mechanically adjusting fiber block positions to achieve coupling, the system uses precisely fabricated lenses with fixed geometric positions that automatically provide the correct coupling alignment when the chip is assembled.
2Stability of the object's composition
If adhesive is used to fix fiber block, then alignment is maintained, but optical loss increases and board space is occupied
Solution Approach 1:
The patent extracts and eliminates the adhesive layer from the optical coupling path. By forming lenses directly on the chip surface, the system removes the need for adhesive-based fiber block fixation, thereby eliminating optical loss associated with adhesive interfaces and freeing up board space.
Solution Approach 2:
The patent introduces lens arrays as an intermediary optical element between the grating couplers and the fiber block. These lenses serve as the mediating component that provides both alignment stability and optical coupling without requiring adhesive, replacing the dual function of adhesive (mechanical fixation and optical coupling).
3Ease of operation
If connector exits horizontally from transceiver, then optical connection is achieved, but valuable board space is consumed
Solution Approach 1:
The patent changes the spatial dimension of connector orientation from horizontal (parallel to board surface) to vertical (perpendicular to board surface). By enabling the connector to exit vertically from the transceiver module, the system maintains optical connection capability while dramatically reducing the horizontal board space footprint, allowing better utilization of board area for other components.
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 solution allows for rapid and accurate formation of lens arrays on silicon photonics chips, reducing optical loss and enabling a more compact design that aligns lenses and gratings with relaxed tolerance requirements, facilitating the use of a connector that plugs from the top, thereby optimizing space usage and improving operational efficiency.
Implementation Method 1
an array of lenses (24) integrally formed with the body (22)... the array of lenses, in operation, couples to an optical fiber connector
Implementation Method 2
dispensing curable material onto said photonics integrated circuit by shaping said curable material into said body and said array of lenses; and curing said material shaped into said body and said array of lenses
Data Source
AI summary
An optical coupling includes a body having a first surface which couples with a photonics integrated circuit and a second surface including an array of lenses integral with the body. The array of lenses couples to an optical fiber connector. The array of lenses may be a linear array. The body may be made of a polymer material, which may be optically cured. The photonics integrated circuit and the optical coupling may be used, for example, in a mobile phone. The optical coupling may be made by shaping curable material on a photonics integrated circuit into a body, and curing the body of curable material. The cured body includes the first surface in contact with the photonics integrated circuit and the second surface including the array of optical lenses to couple with the optical fiber connector.