Waveguide Substrate Routing for Compact Optical Signal Management
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Solution Overview
Problem
The management and organization of multiple optical fibers within enclosures in optical communication networks are challenging due to space constraints and the need for flexible routing, as existing solutions require large and bulky modules that are inefficient in terms of space usage and adaptability.
Innovation Solution
The use of waveguide substrates with integrated waveguide layouts on multiple sides, allowing for various routing schemes such as add/drop waveguides and receive-transmit pairs, and featuring alignment elements like pin bores and slots for precise optical connector alignment, enabling compact and modular optical signal routing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional optical fiber routing using large enclosures is used, then optical signals can be routed between connectors, but the enclosures occupy large space and are bulky
Solution Approach 1:
The patent transitions from two-dimensional fiber routing on flat panels to three-dimensional waveguide routing within a substrate. Waveguides are embedded in multiple layers and routed through the thickness of the substrate, enabling complex optical paths in a compact volume while maintaining routing flexibility.
Solution Approach 2:
The patent nests multiple waveguide layers within a single substrate, with each layer containing multiple waveguides. This nested structure allows numerous optical connections to be packed into a small volume while maintaining the ability to route signals flexibly between different connector interfaces.
2Ease of operation
If multiple optical fibers are managed within enclosures, then optical connections can be provided, but fiber management and organization become challenging
Solution Approach 1:
The patent uses alignment features that replicate the connector interface geometry directly on the substrate surface. Pin bores and alignment slots are positioned to match connector pin locations, enabling automatic alignment without complex manual fiber management. The waveguide endpoints are positioned to correspond with connector fiber positions, simplifying the connection process.
3Volume of moving object
If waveguide substrates with integrated layouts are used, then space is saved and density is improved, but precise alignment between connectors and waveguides is required
Solution Approach 1:
The patent incorporates alignment features (pin bores and alignment slots) during substrate fabrication, before connector assembly. These features are pre-positioned with precise locations corresponding to connector pin positions. The pin bores are drilled and slots are etched at predetermined locations, establishing accurate alignment references in advance of final assembly.
Solution Approach 2:
The patent uses pin bores and alignment slots as intermediary alignment elements between connectors and waveguides. These features act as mediators that translate connector position into precise waveguide alignment. The pin bores receive alignment pins from connectors, and the slots provide tolerance for angular misalignment, bridging the gap between mechanical connector positioning and optical waveguide alignment.
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E~1F
AI summary
Waveguide substrate (100), waveguide substrate assemblies and methods of fabricating waveguide substrates having various waveguide routing schemes are disclosed. In one embodiment, a waveguide substrate (100) includes a first surface (101) and a second surface (102), and a plurality of waveguides (110) within the waveguide substrate (100). The plurality of waveguides (110) defines a plurality of inputs at the first surface (101). A subset of the plurality of waveguides (110) extends to the second surface (102) to at least partially define a plurality of outputs at the second surface (102). In one waveguide routing scheme, at least one branching waveguide (110) extends between one of the first surface (101) and the second surface (102) to a surface (103) other than the first surface (101) and the second surface (102). Another waveguide routing scheme arranges the plurality of waveguides (110) into optical receive- transmit pairs for duplex pairing of optical signals.