Staggered Microlens Optical Interconnect for Expanded Beam Alignment
Solution Overview
Problem
Current expanded beam multiple fiber connectors are limited by the fiber ribbon pitch, requiring manual splitting of fibers for connection, which restricts the beam diameter and increases sensitivity to contamination.
Innovation Solution
An optical interconnect assembly using microlenses and light extractors to redirect and shape optical beams, allowing for connections without fiber splitting and enabling beam diameters greater than the fiber-to-fiber pitch, with staggered microlenses and light extractors on printed circuit boards for alignment and redirection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If current expanded beam multiple fiber connectors are used, then fiber connections can be made, but the beam diameter is limited to 250 microns to match the ribbon pitch
Solution Approach 1:
The patent introduces a second spatial dimension by staggering microlenses in rows offset from each other. This staggered arrangement allows the beam to expand beyond the single-row fiber pitch constraint, achieving beam diameters greater than 250 microns while maintaining alignment through the staggered geometric configuration
Solution Approach 2:
The connector is segmented into multiple rows of staggered microlenses, where each row corresponds to different fibers. This segmentation allows independent optimization of beam expansion in each row while maintaining overall alignment through the staggered pattern
2Area of moving object
If fiber ribbons are manually split into single fibers for connection, then beam diameter can be increased, but the process complexity and time increase
Solution Approach 1:
The microlenses are pre-positioned in a staggered configuration on the connector substrate before fiber insertion. This preliminary arrangement of optical elements enables direct connection of intact fiber ribbons without requiring manual splitting, as the staggered lens pattern pre-establishes the geometric relationship needed for beam expansion
Solution Approach 2:
The staggered microlens pattern creates an optical copy or transformation of the fiber array geometry, allowing the beam to be expanded and repositioned in a staggered pattern that achieves greater diameter without physically separating the fibers
3Reliability
If traditional optical connectors are used, then connections can be made, but sensitivity to dust and contamination increases
Solution Approach 1:
The microlenses serve as intermediary optical elements between the fiber cores and the beam path. By expanding the beam through these intermediary lenses, the system creates a larger optical path that is less sensitive to dust particles and contamination, as the expanded beam can tolerate larger obstructions while maintaining signal integrity
4Object-affected harmful factors
If beam diameter is increased beyond fiber pitch, then contamination resistance improves, but alignment precision requirements increase
Solution Approach 1:
The patent employs asymmetric staggering of microlenses in offset rows rather than a symmetric grid arrangement. This asymmetric configuration provides inherent alignment tolerance, as the staggered pattern creates geometric relationships that are more forgiving of manufacturing variations while still achieving the desired beam expansion and contamination resistance
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 compact, reliable, and low-maintenance optical interconnect that reduces alignment precision requirements, increases tolerance to misalignment, and enhances resistance to contamination, enabling higher data transfer rates in densely packed optical connections.
Implementation Method 1
light traveling within the first optical waveguide enters the second optical waveguide after being redirected by the light extractor of the first optical waveguide, exiting the first optical waveguide, traveling through the first microlens in the plurality of first microlenses corresponding to the first optical waveguide
Implementation Method 2
traveling through the first microlens in the plurality of first microlenses corresponding to the first optical waveguide, traveling through the second microlens in the plurality of second microlenses corresponding to the second optical waveguide
Implementation Method 3
light traveling within the first optical waveguide enters the second optical waveguide after being redirected by the light extractor of the first optical waveguide
Data Source
AI summary
The disclosure generally relates to sets of optical waveguides such as optical fiber ribbons and embedded optical waveguides, and optical interconnects useful for connecting multiple optical waveguides such as in optical fiber ribbon cables and printed circuit boards (PCBs) having optoelectronic capabilities. In particular, the disclosure provides an efficient, compact, and reliable optical waveguide connector that incorporates microlenses and re-directing elements which combine the features of optical waveguide alignment, along with redirecting and shaping of the optical beam.