Stacked Optical Ferrules for Dense On-Board Interconnect Ports
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge in the integrated photonics industry is to increase the number of input/output ports on a microchip without violating size constraints, as standard fiber diameters limit the scalability of linear arrays.
Innovation Solution
Assembling a stack of individual discrete optical ferrules along thickness directions, each with attachment areas for optical waveguides and light redirecting members, allowing central light rays to be redirected and exit through different locations, enabling a two-dimensional array of ports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If standard fiber diameters are used in linear arrays, then the structure is simple to manufacture, but the port density is limited and chip size increases
Solution Approach 1:
The patent transitions from a linear one-dimensional array of optical fibers to a three-dimensional stacked arrangement of ferrules. By stacking multiple ferrules vertically along the thickness direction and using light redirecting members to bend light paths, the system achieves higher port density without increasing the lateral footprint on the chip, effectively moving from 1D to 3D spatial utilization.
Solution Approach 2:
The optical connection system is divided into multiple discrete ferrules, each containing a subset of optical fibers. These ferrules are stacked vertically and independently managed, with each ferrule serving as a separate module that can be precisely positioned and aligned. This segmentation enables higher density while maintaining manufacturing simplicity.
2Quantity of substance
If light rays are redirected through stacked ferrules, then port density increases, but the optical path becomes more complex
Solution Approach 1:
Light redirecting members are introduced as intermediary elements between the optical fibers in upper ferrules and the exit points on the chip. These redirecting members bend the light paths at controlled angles, enabling light from vertically stacked ferrules to reach horizontal exit points on the chip surface. This intermediary mechanism simplifies the overall optical path design compared to direct vertical connections.
3Area of stationary object
If multiple ferrules are stacked vertically, then space utilization improves, but alignment precision requirements increase
Solution Approach 1:
The ferrules are pre-aligned and pre-assembled into stacks before final integration with the chip. Each ferrule is prepared with precise positioning features, and the stacking process is performed as a preliminary assembly step that establishes the vertical arrangement. This preliminary action reduces the alignment precision requirements during the final chip integration 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 approach allows for a denser arrangement of input/output ports by redirecting light rays through a stack of ferrules, optimizing space utilization and increasing port density without increasing chip size.
Implementation Method 1
The light redirecting member is configured to receive, along a first direction, one or more central light rays emitted from a corresponding one or more optical waveguides attached to the optical ferrule and redirect the one or more received central light rays along a different second direction as one or more redirected central light rays
Data Source
AI summary
A stack of the optical ferrules, each of the optical ferrules including a top surface having attachment areas for optical waveguides, a light redirecting member, and a bottom surface having an exit window. When optical waveguides are attached to the attachment areas, central light rays emitted by the optical waveguides are redirected by the light redirecting member and exit the optical ferrule through the exit window. For each pair of adjacent stacked upper and lower optical ferrules, the exiting central light ray of the upper optical ferrule enters the lower optical ferrule through the top surface of the lower optical ferrule and exits the lower optical ferrule through the exit window of the lower optical ferrule. Each of the exiting central light rays of each of the optical ferrules exits the exit window of a lowermost optical ferrule at a different location.