Side Coupling Optical Fiber Assembly with Inclined Facet
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Solution Overview
Problem
Current side-coupling optical fiber packaging technologies face instability and alignment challenges, especially at high speeds, due to the use of metallic elements with thermal expansion and the need for precise positioning, which limits the implementation of flip-chip technology and increases manufacturing costs and time.
Innovation Solution
A side-coupling optical fiber assembly is developed, featuring a first substrate with a groove for the optical fiber and a second substrate that covers and fixes the fiber, with an inclined facet for total internal reflection, allowing for stable and flexible fiber positioning and integration with flip-chip mounting, using adhesion and optical elements like lenses for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic elements with thermal expansion are used for fiber fixation, then airtight packaging is achieved, but fiber positioning stability deteriorates due to thermal expansion and contraction
Solution Approach 1:
The patent extracts the fiber fixation function from the metallic package structure and relocates it to the substrate groove structure. The fiber is fixed directly to the substrate at its end position, separating the fixation function from the metallic packaging elements that cause thermal expansion issues.
Solution Approach 2:
The patent replaces the metallic mechanical fixation system (metal sleeve and solder) with a substrate-based mechanical structure (groove and adhesive). This substitution eliminates the thermal expansion problems associated with metallic elements while maintaining fixation functionality.
2Reliability
If fiber is fixed away from the end position, then airtight packaging is achieved, but coupling precision deteriorates due to fiber end spatial freedom
Solution Approach 1:
The substrate groove is pre-formed at the exact position where the fiber end needs to be fixed. This preliminary preparation ensures that when the fiber is placed and fixed, it is automatically positioned with high precision at the coupling location, eliminating the need for post-positioning adjustments.
3Reliability
If complex metallic fixation structures are used, then airtight packaging is achieved, but device complexity increases
Solution Approach 1:
The patent extracts the fixation function from the complex metallic package structure and implements it directly in the substrate. This eliminates the need for separate metal sleeves, multiple soldering operations, and complex alignment mechanisms, significantly simplifying the overall device structure.
Solution Approach 2:
The patent merges the fiber fixation function with the substrate structure by forming the groove directly in the substrate. This integration eliminates the need for separate fixation components and reduces the number of assembly steps, simplifying both the device structure and manufacturing process.
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 provides a stable and reliable optical fiber coupling, accommodating high-speed requirements and enabling the use of flip-chip technology, reducing manufacturing complexities and costs by ensuring precise fiber positioning and minimizing thermal effects.
Implementation Method 1
The side coupling is realized through an inclined end facet formed on the optical fiber end 140, which satisfies a total-internal-reflection condition.
Data Source
AI summary
A side-coupling optical fiber assembly comprises a first substrate (200), on a surface of which at least one concave groove is provided; an optical fiber (210) disposed in the concave groove; and a second substrate (220) disposed on the first substrate (200) and pressed on the optical fiber (210). The end of the optical fiber (210) between the first substrate (200) and the second substrate (220) is set as a slant surface (240), which is used for performing total reflection for the light beam transmitted in the optical fiber (210). A method for making the side-coupling optical fiber assembly is provided.