Waveguide Connector With Staggered Ridges For Polymer Alignment
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Solution Overview
Problem
Existing connectors for silicon photonics devices lack precision in aligning optical waveguides, particularly when using polymer materials, which are insufficiently dimensionally precise compared to inorganic materials, and struggle to accurately position multiple waveguides within a polymer ribbon relative to the connector.
Innovation Solution
A connector with a recessed portion featuring staggered ridges to support and position waveguides within a polymer ribbon, combined with a backup member that interposes between the connector and the waveguides, allowing for precise alignment of the waveguides relative to the connector, with a precision of up to ±2.0 μm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polymer materials are used to make connectors, then flexibility and ease of manufacture are improved, but manufacturing precision and dimensional accuracy deteriorate
Solution Approach 1:
The connector employs a composite structure combining polymer material with metal inserts or reinforcement elements. The polymer provides flexibility and ease of manufacture, while the metal components provide dimensional stability and precision for waveguide positioning, achieving both ease of manufacture and manufacturing precision simultaneously
Solution Approach 2:
The connector design applies different material properties to different regions: the bulk polymer material provides flexibility and ease of manufacturing, while specific localized regions contain metal reinforcement or precision-machined features that provide the dimensional accuracy needed for waveguide alignment, thus resolving the contradiction between ease of manufacture and manufacturing precision
2Measurement precision
If traditional alignment methods are used, then device complexity is reduced, but alignment precision deteriorates
Solution Approach 1:
The connector incorporates pre-formed ridges and grooves that are manufactured in advance with precise dimensions and positions. These alignment features are built into the connector structure during manufacturing, eliminating the need for complex real-time alignment procedures and achieving high alignment precision without proportionally increasing device complexity
Solution Approach 2:
The staggered ridge and groove structure enables self-alignment of the waveguide within the connector. The geometric interlocking features automatically guide the waveguide into the correct position when mated, providing self-aligning functionality that achieves high precision without requiring complex external alignment mechanisms or procedures
Data Source
AI summary
Various embodiments are directed to a connector for coupling optical signals to a semiconductor device. In one embodiment, the connector includes a connector member having a recessed portion to arrange a plurality of waveguides formed side-by-side in a transverse direction. A backup member is arranged within the recessed portion interposing the plurality of waveguides between the connector member and the backup member. The recessed portion includes a plurality of ridges arranged in a staggered pattern relative to the plurality of waveguides for positioning the plurality of waveguides relative to the connector.