Fiber optic-to-waveguide coupling assembly with overlap for edge coupling

1. A fiber optic-to-waveguide coupling assembly, comprising:

a first coupler comprising:

a first substrate comprising a first surface; and

at least one data fiber positioned proximate the first surface; and

an interposer comprising a second surface and at least one waveguide positioned proximate the second surface;

wherein at least a first portion of the first surface of the first substrate of the first coupler is positioned proximate at least a second portion of the second surface of the interposer to form a first overlap between the first portion of the first surface and the second portion of the second surface to align the at least one data fiber of the first coupler with the at least one waveguide of the interposer to allow for transmitting a signal between the at least one data fiber and the at least one waveguide;

wherein the at least one data fiber of the first coupler does not extend into the first overlap and the at least one waveguide of the interposer extends into the first overlap.

2. The fiber optic-to-waveguide coupling assembly of claim 1 , wherein the first surface of the first substrate contacts the second surface of the interposer.

3. The fiber optic-to-waveguide coupling assembly of claim 1 , wherein the first surface and the second surface are planar.

4. The fiber optic-to-waveguide coupling assembly of claim 1 , wherein the second surface of the interposer comprises at least one waveguide channel, the at least one waveguide positioned in the at least one waveguide channel.

5. The fiber optic-to-waveguide coupling assembly of claim 1 , wherein the at least one waveguide comprises a glass waveguide.

6. The fiber optic-to-waveguide coupling assembly of claim 1 , wherein the first substrate defines at least one mounting groove and the at least one data fiber is positioned in the at least one mounting groove.

7. The fiber optic-to-waveguide coupling assembly of claim 6 , wherein the at least one mounting groove does not extend the entire length of the first substrate.

8. The fiber optic-to-waveguide coupling assembly of claim 7 , wherein the at least one mounting groove terminates at a trench that is transverse to the at least one mounting groove.

9. The fiber optic-to-waveguide coupling assembly of claim 1 , wherein the first substrate comprises at least one substrate alignment fiducial on the first surface.

10. The fiber optic-to-waveguide coupling assembly of claim 1 , wherein the first substrate comprises at least one substrate alignment groove in the first surface.

11. The fiber optic-to-waveguide coupling assembly of claim 10 ,

wherein the first substrate comprises at least one mounting groove in the first surface and the at least one data fiber is positioned in the at least one mounting groove; and

wherein a depth of the at least one substrate alignment groove is greater than a depth of the at least one mounting groove.

12. The fiber optic-to-waveguide coupling assembly of claim 10 ,

wherein the first substrate comprises a plurality of evenly-spaced mounting grooves in the first surface; and

wherein a spacing between the evenly-spaced mounting grooves is same as a spacing between the at least one substrate alignment groove and an adjacent evenly-spaced mounting groove.

13. The fiber optic-to-waveguide coupling assembly of claim 10 , wherein the interposer further comprises at least one interposer alignment fiducial on the second surface of the interposer, the at least one interposer alignment fiducial is positioned to facilitate alignment between the at least one data fiber and the at least one waveguide when the at least one interposer alignment fiducial is aligned with the at least one substrate alignment groove.

14. The fiber optic-to-waveguide coupling assembly of claim 13 , wherein the at least one interposer alignment fiducial is photolithographically defined.

15. The fiber optic-to-waveguide coupling assembly of claim 13 , wherein the interposer comprises a material that is transparent to visible light.

16. The fiber optic-to-waveguide coupling assembly of claim 10 , wherein the first coupler further comprises at least one alignment cylinder positioned in the at least one substrate alignment groove.

17. The fiber optic-to-waveguide coupling assembly of claim 16 , wherein the at least one alignment cylinder comprises a non-data optical fiber.

18. The fiber optic-to-waveguide coupling assembly of claim 16 , wherein a diameter of the at least one alignment cylinder is the same as a diameter of the at least one data fiber.

19. The fiber optic-to-waveguide coupling assembly of claim 16 , wherein the interposer defines at least one interposer alignment groove configured to receive at least a portion of the at least one alignment cylinder to align the at least one data fiber of the first coupler with the at least one waveguide of the interposer.

20. The fiber optic-to-waveguide coupling assembly of claim 1 , wherein the first coupler further comprises a cover, and wherein the at least one data fiber is positioned between the cover and the first substrate.

21. The fiber optic-to-waveguide coupling assembly of claim 20 , wherein the cover comprises at least one v-groove and the at least one data fiber at least partially positioned within the at least one v-groove.

22. The fiber optic-to-waveguide coupling assembly of claim 1 ,

wherein the at least one data fiber of the first coupler further comprises a plurality of data fibers; and

wherein the first coupler further comprises a plurality of pitch spacing fibers alternatingly interposed between the plurality of data fibers.

23. A fiber optic-to-waveguide coupling system, comprising:

a first coupler comprising:

a first substrate comprising a first plurality of mounting grooves defined in a first surface of the first substrate; and

a fiber array comprising a plurality of data fibers, each of the plurality of data fibers positioned in one of the first plurality of mounting grooves;

a second coupler comprising a plurality of silicon waveguides; and

an interposer comprising:

a plurality of waveguide channels defined in a second surface of the interposer;

a plurality of waveguides, wherein each of the plurality of waveguides is positioned in one of the plurality of waveguide channels;

wherein at least a portion of the first surface of the first substrate of the first coupler is positioned proximate at least a portion of the second surface of the interposer to form a first overlap therebetween to align the plurality of data fibers of the first coupler with the plurality of waveguides of the interposer; and

wherein at least a portion of the silicon waveguide of second coupler is positioned proximate at least a portion of the second surface of the interposer to form a second overlap therebetween to evanescently couple signals from the plurality of waveguides to the plurality of silicon waveguides;

wherein the at least one data fiber does not extend into the first overlap.

24. The fiber optic-to-waveguide coupling system of claim 23 , wherein the first surface of the first substrate contacts the second surface of the interposer.

25. A method of manufacturing a fiber optic-to-waveguide coupling assembly, comprising:

positioning at least one data fiber proximate a first surface of a first substrate of a first coupler;

positioning at least one waveguide proximate a second surface of an interposer;

aligning the at least one data fiber of the first coupler with the at least one waveguide of the interposer by placing at least a portion of the first surface of the first substrate of the first coupler in contact with at least a portion of the second surface of the interposer to form a first overlap therebetween; and

aligning the at least one waveguide of the interposer with at least one silicon waveguide of a second coupler by placing at least a portion of the second surface of the interposer in contact with the second coupler;

wherein the at least one data fiber of the first coupler does not extend into the first overlap and the at least one waveguide of the interposer extends into the first overlap.