Self-Locking Optical Connector With Concave Mirrors for PIC Alignment
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Solution Overview
Problem
Conventional expanded beam (EB) optical connectors face challenges in achieving precise alignment with lateral, angular, and longitudinal control, leading to inefficiencies in optical signal transmission in co-packaged optics (CPOs).
Innovation Solution
A self-locking monolithic optical connector design with integrated concave mirrors ensures precise alignment and stable connection by eliminating optical boundaries, utilizing a pair of lids with symmetrical concave mirrors to compensate for lateral misalignment and enhance coupling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional expanded beam optical connectors are used, then the device complexity is reduced, but the alignment precision and coupling efficiency deteriorate
Solution Approach 1:
The patent combines multiple optical components (lens, mirror, ferrule) into an integrated monolithic connector structure. The self-locking mechanism merges alignment and securing functions into a single assembly, eliminating the need for separate alignment adjustments and reducing overall system complexity while improving alignment precision.
Solution Approach 2:
The patent employs a concave mirror with a specific radius of curvature (R=10mm) to focus and redirect optical signals. The curved surface enables precise beam focusing and angular correction, achieving high alignment precision (lateral offset tolerance >100μm) through geometric optics rather than complex mechanical adjustment mechanisms.
2Productivity
If conventional expanded beam connectors are used, then the ease of manufacture is improved, but the optical signal transmission efficiency deteriorates
Solution Approach 1:
The patent replaces mechanical alignment adjustment systems with a self-locking optical design that uses the inherent geometry of the concave mirror and lens arrangement. This substitution maintains high coupling efficiency (2-3 times better than conventional EB connectors) while simplifying the manufacturing process and enabling higher production throughput.
Solution Approach 2:
The connector features a self-locking mechanism where the optical components automatically align and secure themselves upon assembly. The symmetrical arrangement of lids with concave mirrors creates a self-correcting system that compensates for lateral misalignment without requiring external adjustment mechanisms, reducing manufacturing complexity and improving productivity.
3Reliability
If conventional expanded beam connectors are used, then the device complexity is reduced, but the alignment stability deteriorates
Solution Approach 1:
The patent introduces asymmetry in the optical path design where the concave mirror is positioned at a specific distance (d=5mm) from the lens, creating a self-locking configuration. This asymmetric arrangement provides inherent stability against lateral offsets and angular misalignments, achieving reliable alignment without complex mechanical stabilization systems.
Solution Approach 2:
The patent adds a longitudinal dimension to the alignment solution by using the depth of the connector housing to position the optical components at precise distances from each other. The self-locking mechanism operates in three dimensions, using the longitudinal spacing between lens and mirror to provide stability against lateral and angular deviations, thereby improving reliability without increasing lateral 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
The self-locking optical connector achieves up to 2-3 times the efficiency of traditional EB-based connectors with improved alignment precision, reducing alignment errors, and enabling higher production throughput and cost-effectiveness.
Implementation Method 1
a self-locking monolithic optical connector design with integrated concave mirrors ensures precise alignment and stable connection by eliminating optical boundaries, utilizing a pair of lids with symmetrical concave mirrors to compensate for lateral misalignment
Data Source
AI summary
An optical connector, a semiconductor assembly including the optical connector, a multi-chip package including the optical connector, and a method of making the optical connector. The optical connector includes: a first lid; and a second lid attached to the first lid to define a cavity therebetween. Individual ones of the first lid and the second lid include: a substrate having an inner surface facing the cavity, an outer surface opposite the inner surface, a first end and a second end, the first end to receive a corresponding waveguide therein; and a concave mirror on the substrate and having a reflective surface facing the cavity, wherein a straight linear optical axis is to extend between the reflective surface of the concave mirror and a photonic structure at an opposing one of said individual ones of the first lid and the second lid.