Waveguide Connector Elements for Optical Assembly Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The alignment of optical waveguides in optical transceiver devices, such as silicon-based photonic devices, requires expensive and time-consuming active alignment processes due to the small size of laser diodes and photodiodes, leading to increased costs and reduced throughput in optical communication systems.
Innovation Solution
The development of waveguide connector elements with laser-written optical waveguides that can be attached to optical printed circuit boards, providing a compact, low-cost, high-density connection to external optical fiber arrays, and incorporating beam expansion lenses to minimize sensitivity to lateral misalignments, enabling efficient optical coupling and conversion between different waveguide pitches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If active alignment processes are used for waveguide alignment, then alignment precision is improved, but manufacturing cost and time consumption increase
Solution Approach 1:
The patent applies preliminary action by pre-forming waveguides in the connector element before final assembly. The waveguides are created in advance with predetermined positions and orientations, eliminating the need for complex active alignment processes during manufacturing. This allows the connector to be assembled without requiring expensive alignment equipment or time-consuming adjustment procedures.
Solution Approach 2:
The patent implements self-service through self-aligning features built into the connector structure. Mechanical guides, registration features, and geometric constraints are incorporated into the connector design, allowing the waveguides to automatically align with mating components during assembly. This eliminates the need for external alignment equipment and operators to perform manual adjustment.
2Volume of moving object
If waveguide size is reduced to enable compact transceivers, then device size is reduced, but alignment difficulty increases
Solution Approach 1:
The patent applies local quality by providing different structural characteristics at different locations within the connector. The waveguide regions have precise dimensional control and specialized geometries optimized for their specific coupling functions, while other portions of the connector provide mechanical support and alignment features. This allows compact waveguide dimensions while maintaining alignment precision through locally optimized structures.
Solution Approach 2:
The patent uses preliminary action by pre-positioning and pre-aligning the compact waveguides within the connector housing during manufacturing. The waveguides are embedded in predetermined locations with precise orientations established before final assembly. This preliminary positioning eliminates the need for field alignment of the compact waveguides, maintaining precision despite their small size.
3Manufacturing precision
If beam expansion lenses are added to minimize misalignment sensitivity, then alignment tolerance is improved, but device complexity increases
Solution Approach 1:
The patent merges the beam expansion lens function with the waveguide structure itself. Rather than adding separate lens components, the waveguide geometry is designed to inherently expand or shape the optical beam, providing misalignment tolerance through the waveguide's own structure. This integration eliminates additional components while achieving the desired optical performance.
Solution Approach 2:
The patent applies parameter changes by modifying the waveguide dimensional parameters, particularly the core diameter and numerical aperture, to optimize beam expansion characteristics. By adjusting these geometric parameters during the waveguide formation process, the connector achieves increased alignment tolerance through controlled beam shaping without adding complex optical components.
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 reduces the complexity and cost of alignment processes, enhances the reliability and density of optical interconnections, and allows for efficient optical coupling with improved alignment tolerances, thereby increasing the throughput and reducing the overall packaging volume of optical communication systems.
Implementation Method 1
a laser written optical waveguide optically coupled to an end of the pre-existing optical waveguide and extending toward one of the first end face and the second end face
Implementation Method 2
beam expansion lenses may also be laser written into the device to minimize sensitivity to lateral misalignments
Data Source
AI summary
Optical waveguide connector elements for optical coupling optical components of an optical assembly, such as the edge coupling of optical printed circuit boards. In one embodiment, a waveguide connector element includes a first end face and a second end face, a pre-existing optical waveguide within or on a surface of the waveguide connector element, and a laser written optical waveguide optically coupled to an end of the pre-existing optical waveguide and extending toward one of the first end face and the second end face.