Self-Aligning Optical Coupling for Relaxed Assembly Tolerance
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Solution Overview
Problem
Challenges exist in coupling optical signals and integrating optical components with electrical components, particularly in achieving accurate alignment and reducing assembly tolerance requirements.
Innovation Solution
The implementation of a self-aligning optical surface coupling scheme using a novel mirror arrangement, which transfers accuracy and tolerance requirements from the assembly domain to the production domain, allowing for relaxed assembly tolerances and enabling optical and electro-optical packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional side coupling methods are used to couple optical signals, then optical coupling can be achieved, but assembly tolerance requirements become extremely stringent and alignment precision must be very high
Solution Approach 1:
The patent introduces an intermediary optical component (such as a lens or optical element) between the optical fiber and the target optical component. This intermediary element facilitates the coupling of optical signals while significantly relaxing the alignment tolerance requirements. The intermediary acts as a mediator that transforms the stringent side-coupling alignment requirements into more manageable parameters, enabling easier assembly while maintaining optical coupling effectiveness.
Solution Approach 2:
The patent transitions from traditional lateral/side coupling to vertical coupling by changing the spatial dimension of optical signal transmission. Instead of aligning optical fibers horizontally alongside optical components, the invention directs optical signals vertically downward onto the optical components. This dimensional change fundamentally alters the alignment requirements, replacing the need for precise lateral positioning with simpler vertical alignment, thereby dramatically improving ease of manufacture.
2Reliability
If highly accurate alignment is required for optical coupling, then coupling efficiency is maintained, but assembly time increases and productivity decreases
Solution Approach 1:
The patent incorporates preliminary alignment features directly into the optical component structure during the manufacturing process. These pre-integrated alignment features (such as positioning structures or alignment marks) enable rapid and accurate alignment during assembly without requiring time-consuming manual adjustment. By performing alignment preparation in advance during production, the system maintains high coupling efficiency while dramatically reducing assembly time and increasing productivity.
3Adaptability or versatility
If traditional optical coupling methods are used, then optical signal transmission is achieved, but the integration of optical and electrical components becomes complex and difficult
Solution Approach 1:
The patent merges optical components and electrical components into a single integrated package structure. The optical components (such as lasers, modulators, or detectors) are directly coupled with their corresponding electrical components (such as drivers or readout circuits) within the same packaging environment. This merging eliminates the need for separate coupling mechanisms and intermediate interfaces, thereby simplifying the overall integration process while enhancing the adaptability and versatility of the electro-optical system.
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 approach simplifies the assembly process by reducing the need for precise alignment during assembly, facilitating high-volume packaging of photonic devices and efficient integration of optical and electrical components, while allowing for out-of-plane component connections.
Implementation Method 1
The surface coupling scheme of the present disclosure may be achieved with a novel mirror arrangement
Data Source
AI summary
Apparatuses, systems and methods for optical coupling, optical integration, electro-optical coupling, and electro-optical packaging are described herein. Optical couplers may comprise various optical elements (e.g., mirrors as described herein) to relax optical assembly requirements and improve producibility. Optical couplers may improve fiber-to-chip, fiber-to-fiber and chip-to-chip optical connection. Optical couplers and optical components may be used to improve integration of, connection of, and/or packaging of optical systems and/or components with electrical systems and/or components.