Polymer Waveguide Connector Assembly with Elastomer Cap

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Solution Overview

Problem

Existing polymer waveguide connectors face challenges in precise positioning, with errors exceeding micrometer levels, leading to signal loss and contamination issues that affect adiabatic coupling between polymer and silicon waveguides.

Innovation Solution

A waveguide connector assembly device featuring an elastomer cap with guiding pins and an inner wall for precise alignment and sealing, utilizing differing coefficients of thermal expansion to align components and prevent contamination, along with increased thickness of the waveguide for stability and consistency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If existing polymer waveguide connectors are used for assembly, then the connector can be manufactured, but positioning errors exceed micrometer levels leading to signal loss

Engineering Contradiction:

Improvepositioning precisionVSAvoidsignal transmission reliability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent utilizes differential thermal expansion between the polymer waveguide and the ferrule material. By heating the assembly to a specific temperature, the polymer waveguide expands at a different rate than the ferrule, enabling precise alignment and positioning of the waveguide core within the ferrule hole. This thermal expansion mechanism allows positioning precision below one micrometer, resolving the contradiction between manufacturability and positioning precision.

Inventive Principle:

Principle #37Thermal expansion

2Object-affected harmful factors

If polyimide cover films or adhesive tape are placed over the polymer waveguide connector core array to prevent contamination, then contamination is prevented, but the polymer waveguide connector may tear or have residual glue affecting adiabatic coupling efficiency

Engineering Contradiction:

Improvecontamination protectionVSAvoidadiabatic coupling efficiency

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent applies a protective coating to the polymer waveguide connector core array before assembly into the ferrule. This preliminary protective layer prevents contamination during the assembly process and handling, while being designed to be removed or integrated without causing tearing or residual adhesive that would affect the adiabatic coupling between the polymer waveguide and silicon waveguide.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces a protective coating as an intermediary layer between the polymer waveguide core and the external environment. This coating serves as a mediator that protects against contamination during assembly while being compatible with the subsequent adiabatic coupling process, preventing both tearing and residual glue issues.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the polymer waveguide connector is assembled without overclad to enable direct contact with silicon waveguide for high efficient adiabatic coupling, then adiabatic coupling efficiency is maximized, but the connector becomes susceptible to contamination

Engineering Contradiction:

Improveadiabatic coupling efficiencyVSAvoidcontamination susceptibility

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

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

Achieves precise positioning errors below one micrometer, maintaining pristine surface areas for photonic packaging and enhancing adiabatic coupling efficiency by preventing contamination and ensuring accurate alignment of waveguide cores.

Implementation Method 1

heating the polymer waveguide and the ferrule to a first temperature, the ferrule comprising alignment features and having a different coefficient of thermal expansion from the polymer waveguide, wherein the alignment features of the polymer waveguide align with the alignment features of the ferrule when the polymer waveguide and the ferrule are heated to the first temperature

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS10281658B2Single-mode polymer waveguide connector assembly device

Publication Date: 2019.05.07 INTERNATIONAL BUSINESS MACHINE CORPORATION

AI summary

Waveguide connector assembly device and methods of forming waveguide connectors include a cap having an inner portion to protect a connection end face of a polymer waveguide, wherein the cap includes one or more insertion structures to position the polymer waveguide in relation to one or more components of an assembled connector, and an inner wall to seal around the assembled connector to prevent contaminants from entering the inner portion.