Removable Optical Connector Alignment for Grating Couplers
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Solution Overview
Problem
Optical connectors used in optical circuits are not robust enough to withstand procedures like flip chip solder reflow and have alignment issues, leading to insertion loss and manufacturing errors.
Innovation Solution
The use of removably coupled optical connectors with mating structures and standoffs, along with collimating lenses and reflectors, allows for relaxed alignment tolerances and reduced insertion loss by enabling precise alignment and efficient light coupling between optical fibers and grating couplers on a substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If optical connectors are permanently attached to the substrate using optical adhesive, then alignment precision is improved, but the connectors cannot withstand manufacturing procedures like flip chip solder reflow and cannot be repositioned
Solution Approach 1:
The optical connection system is divided into separate components: the optical circuit on the substrate and the optical connector on the interposer, which are coupled through mating structures but remain physically separable. This segmentation allows the connector to be repositioned or removed without damaging the substrate, while still achieving precise alignment through the interlocking alignment structures.
Solution Approach 2:
An interposer structure acts as an intermediary between the substrate and the optical connector. The interposer contains alignment structures that mate with corresponding structures on both the substrate and connector, enabling precise alignment while allowing the connector to be attached or detached from the interposer without permanently bonding to the substrate.
2Adaptability or versatility
If optical connectors are removably coupled to the substrate, then adaptability and repositionability are improved, but alignment precision deteriorates leading to insertion loss
Solution Approach 1:
Alignment structures such as protrusions and recesses are pre-formed on the substrate and interposer during manufacturing. These pre-formed features guide the optical connector into precise alignment during the attachment process, eliminating the need for complex alignment procedures while maintaining high positioning accuracy even with removable coupling.
Solution Approach 2:
The patent replaces complex mechanical alignment systems with simple geometric mating features (protrusions fitting into recesses, tapered surfaces). These simplified mechanical features provide self-aligning capabilities that ensure precise positioning without requiring sophisticated adjustment mechanisms, thereby maintaining alignment precision while enabling removable coupling.
3Loss of energy
If tight alignment tolerances are used for optical coupling, then insertion loss is reduced, but manufacturing complexity and difficulty increase
Solution Approach 1:
The alignment system extends into the vertical dimension with multi-level alignment structures, including protrusions and recesses at different heights and tapered surfaces. This three-dimensional alignment approach provides multiple degrees of freedom for alignment, enabling tight coupling tolerances to be achieved more easily than with two-dimensional planar alignment alone, thereby reducing insertion loss without proportionally increasing manufacturing complexity.
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 enhances the robustness of optical connectors, reduces insertion loss, and improves manufacturing quality by ensuring accurate alignment and efficient light transmission, even under non-perpendicular angles, thereby increasing the reliability of optical modules.
Implementation Method 1
grating couplers configured to efficiently couple light between the optical circuits and the optical connectors
Implementation Method 2
The optical connectors may at least partially house a respective optical fiber and/or collimating lens
Data Source
AI summary
Optical modules are disclosed. An example optical module includes a substrate comprising a grating coupler, an optical connector removably coupled to the substrate adjacent the grating coupler to optically couple the optical connector and the grating coupler and an integrated circuit coupled to the substrate.