Tapered D-Shaped Fiber Evanescent Coupling

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Solution Overview

Problem

Conventional methods for coupling optical fibers to photonic integrated circuits (PICs) face challenges such as high signal loss, complex alignment requirements, and increased fabrication complexity and cost, especially when dealing with arrays of optical fibers and waveguides.

Innovation Solution

The use of a tapered D-shaped optical fiber with a non-circular cross-section, featuring a D-shaped cladding and a core with a substantially flat surface angled relative to the fiber axis, allows for efficient evanescent coupling with nanophotonic waveguides on PICs, reducing alignment complexity and coupling loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional optical fiber coupling methods are used, then alignment is straightforward, but coupling loss increases to around 1 dB

Engineering Contradiction:
Improvecoupling lossVSAvoidalignment complexity
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The patent applies asymmetry by transforming the conventional circular optical fiber into a D-shaped fiber with a flat surface. This asymmetric geometry enables direct evanescent coupling with the waveguide's flat interface, eliminating the need for complex alignment procedures while reducing coupling loss. The flat surface of the D-shaped fiber aligns naturally with the waveguide, making the coupling process as simple as placing the fiber against the chip surface.

Inventive Principle:
Principle #4Asymmetry

Solution Approach 2:

The patent changes the geometric parameters of the optical fiber by tapering it to create a gradually narrowing structure. This parameter change allows the fiber mode field to adiabatically transform and match the waveguide mode, significantly reducing coupling loss. The taper ratio and length are optimized parameters that enable efficient energy transfer from the fiber to the waveguide.

Inventive Principle:
Principle #35Parameter changes

2Loss of energy

If high-precision alignment methods are used, then coupling loss decreases, but fabrication complexity and cost increase

Engineering Contradiction:
Improvecoupling lossVSAvoidfabrication complexity
Core Design Contradiction:
Loss of energyVSEase of manufacture

Solution Approach 1:

The D-shaped asymmetric fiber geometry is designed to naturally align with the waveguide without requiring precision alignment mechanisms. This geometric design inherently guides the fiber into the correct position, eliminating the need for complex alignment fixtures or procedures during fabrication, thereby reducing both complexity and cost.

Inventive Principle:
Principle #4Asymmetry

Solution Approach 2:

The tapered D-shaped fiber structure is self-aligning through its geometry. The flat surface and taper angle cause the fiber to naturally settle into the correct position against the waveguide during simple placement, making the system self-aligning without external alignment equipment or complex fabrication processes.

Inventive Principle:
Principle #25Self-service

3Loss of energy

If conventional circular fiber is used, then manufacturing is simple, but evanescent coupling efficiency decreases

Engineering Contradiction:
Improveevanescent coupling efficiencyVSAvoidfiber manufacturing
Core Design Contradiction:
Loss of energyVSEase of manufacture

Solution Approach 1:

The D-shaped asymmetric cross-section is manufactured using modified fiber drawing techniques where the preform is shaped asymmetrically before drawing. This manufacturing method, while slightly more complex than conventional circular fiber, is still relatively simple and enables efficient evanescent coupling by providing a flat surface that interfaces directly with the waveguide.

Inventive Principle:
Principle #4Asymmetry

Solution Approach 2:

The fiber manufacturing process is modified by changing the cross-sectional shape parameter from circular to D-shaped and by introducing a taper parameter. These parameter changes are achieved through controlled fiber drawing processes that can produce the asymmetric tapered structure in a relatively straightforward manner, enabling efficient coupling.

Inventive Principle:
Principle #35Parameter changes

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 results in significantly reduced coupling loss, simplified alignment processes, and cost-effective manufacturing, enabling efficient optical signal transmission between optical fibers and PICs, even for arrays with a large number of waveguides.

Implementation Method 1

allows for efficient evanescent coupling with nanophotonic waveguides on PICs

Methodology Applied
Scientific EffectEvanescent coupling:

Data Source

PatentUS20250155645A1Tapered fiber with a non-circular cross-section
Publication Date: 2025.05.15 CORNING INC
  • US20250155645A1 patent drawing
  • US20250155645A1 patent drawing
  • US20250155645A1 patent drawing

AI summary

A fiber to waveguide coupler is provided that includes an optical fiber having a core and a cladding. One end of the optical fiber is tapered and has a non-circular cross-section. The optical fiber defines a stripped portion to expose the at least one substantially flat surface of the fiber. A waveguide is configured to be evanescently coupled with the exposed at least one substantially flat surface of the fiber.