Silicon Fiber Optic Platform with Orthogonal Reflection
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Solution Overview
Problem
Current fiber optic cabling systems face challenges in precise alignment and anti-reflection coating due to micron-level position tolerances and the need for 6-axis placement control, leading to optical losses and noise, especially in microscale optical communication applications where thin film stacks are difficult to fabricate on non-exposed surfaces.
Innovation Solution
A silicon-based platform with etched surfaces and reflective/refractive surfaces is used to support fiber optic cables, featuring trenches and ball lenses for precise alignment and anti-reflection coating, allowing for low-loss coupling of light into optical fibers, with KOH etched pockets for seating ball lenses and an integrated prism to redirect light orthogonally.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional alignment processes are used for fiber optic cabling, then optical power loss is minimized through tedious alignment, but manufacturing complexity and time increase significantly due to micron-level position tolerances and 6-axis placement control requirements
Solution Approach 1:
The fiber optic cable assembly includes self-aligning features such as alignment grooves, positioning protrusions, and mechanical coupling structures that automatically align the fiber with the laser source and photonic chip without requiring external alignment tools or procedures. The design enables the system to align itself through inherent geometric constraints and mechanical interlocks.
Solution Approach 2:
The patent replaces complex mechanical alignment procedures with integrated mechanical structures built into the fiber optic assembly. Instead of using separate alignment tools and procedures, the alignment function is embedded in the physical structure through precision-machined features that guide and constrain components into proper alignment during assembly.
2Manufacturing precision
If micron-level alignment precision is achieved through traditional methods, then optical performance is optimized, but manufacturing cost and time increase due to the need for specialized alignment equipment and procedures
Solution Approach 1:
Alignment features such as grooves, protrusions, and positioning structures are pre-integrated into the fiber optic cable assembly during manufacturing. This preliminary incorporation of alignment functionality eliminates the need for time-consuming alignment procedures during system assembly, as components are designed to self-align through their inherent geometric features.
Solution Approach 2:
The patent combines multiple functions into the fiber optic assembly structure itself. Alignment features, mechanical coupling elements, and positioning structures are merged into a single integrated assembly rather than being separate components requiring sequential adjustment. This consolidation enables faster assembly while maintaining precision.
3Loss of energy
If anti-reflection coatings are applied to manage optical losses, then optical performance improves, but manufacturing complexity increases when coatings must be applied to non-exposed surfaces in complex systems
Solution Approach 1:
The patent employs reflective surfaces positioned at strategic angles (such as 45-degree angles) to redirect optical paths. By changing the dimensional orientation of reflective surfaces, the design manages reflections and directs light through alternative pathways, reducing the need for anti-reflection coatings on difficult-to-access surfaces while maintaining optical performance.
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 platform enables precise, low-cost, and efficient alignment of optical components with sub-micron precision, reducing optical losses and facilitating high-quality anti-reflection coatings, thereby enhancing data integrity and system throughput in optical communication systems.
Implementation Method 1
a reflecting surface formed in the top planar surface configured to reflect radiation by total internal reflection, wherein the reflecting surface is configured to direct radiation travelling in a first direction into a second direction, substantially orthogonal to the first direction
Data Source
AI summary
Described here is a platform for supporting a fiber optic cable. The platform may be made on a silicon wafer using silicon lithographic processing techniques. The platform may include a substrate having a top planar surface; a trench formed in the substrate in the top planar surface and dimensioned to accept a fiber optic cable carrying radiation; and a reflecting surface formed in the top planar surface, wherein this reflecting surface is configured to reflect the radiation by total internal reflection, wherein the reflecting surface is configured to direct radiation travelling in a first direction into a second direction, substantially orthogonal to the first direction.