IP Library › Granted Patent US 12,461,321
Granted Patent B2
US 12,461,321 · App. 17/824,854 · Granted Nov 4, 2025

Optical fiber-to-chip interconnection

Inventors: Clinton Randy Giles (Watchung, NJ); Peter Johannes Winzer (Aberdeen, NJ); Ron Zhang (Sunnyvale, CA); Peter James Pupalaikis (Ramsey, NJ); Lukas Elsinger (Ghent, BE)
Assignee: Nubis Communications, Inc.
G02B6/4227
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Quick Facts
Patent No.
US 12,461,321
App. No.
17/824,854
Granted
Nov 4, 2025
Kind
B2
Abstract

A method of assembling an optical device including: providing a photonic integrated circuit including a plurality of vertical-coupling elements disposed along a main surface of the photonic integrated circuit; attaching an optical subassembly to the photonic integrated circuit; removably connecting a fiber connector to a ferrule frame, in which the fiber connector is attached to an array of optical fibers; aligning the ferrule frame to the optical subassembly using an active alignment process; and securely connecting the ferrule frame to the optical subassembly after the active alignment process.

Claims (101)

1 . A method comprising:

providing a photonic integrated circuit including a plurality of vertical-coupling elements disposed along a main surface of the photonic integrated circuit;

attaching an optical subassembly to the photonic integrated circuit;

removably connecting a fiber connector to a ferrule frame, wherein the fiber connector is attached to an array of optical fibers;

aligning the ferrule frame to the optical subassembly using an active alignment process; and

securely connecting the ferrule frame directly to the optical subassembly after the alignment process;

wherein the optical subassembly comprises a first lens array, a second lens array, and a beam displacer, and the active alignment process comprises projecting light from the array of optical fibers through the first lens array, the beam displacer, and the second lens array to the plurality of vertical-coupling elements, including passing light from at least one of the optical fibers through a corresponding lens to a corresponding vertical-coupling element.

2 . The method of claim 1 wherein the active alignment process includes transmitting light between at least one optical fiber and the photonic integrated circuit.

3 . The method of claim 2 wherein the active alignment process comprises:

transferring light between at least one optical fiber in the array of optical fibers and the photonic integrated circuit through the optical subassembly and at least one of the vertical-coupling elements, and

adjusting a position of the ferrule frame relative to the optical subassembly based on at least one characteristic of the light transferred between the at least one optical fiber and the photonic integrated circuit.

4 . The method of claim 1 , comprising removing the fiber connector from the ferrule frame.

5 . The method of claim 1 wherein the ferrule frame comprises an opening to allow light from the array of optical fibers to be transmitted to the optical subassembly.

6 . The method of claim 5 , comprising passing a portion of the optical subassembly through the opening of the ferrule frame and positioning an end of the fiber connector in proximity to the optical subassembly.

7 . The method of claim 5 , comprising passing a portion of the fiber connector through the opening of the ferrule frame and positioning an end of the fiber connector in proximity to the optical subassembly.

8 . The method of claim 1 wherein removably connecting the array of optical fibers to the ferrule frame comprises at least one of (i) using one or more alignment pins to align the array of optical fibers to the ferrule frame, (ii) using one or more clamps to secure the array of optical fibers to the ferrule frame, (iii) using one or more magnets to connect the array of optical fibers to the ferrule frame, or (iv) using removable adhesive to connect the array of optical fibers to the ferrule frame.

9 . The method of claim 1 wherein the array of optical fibers comprises a two-dimensional array of optical fibers.

10 . The method of claim 9 wherein the two-dimensional array of optical fibers comprises at least two rows of optical fibers.

11 . The method of claim 1 wherein the array of optical fibers comprises at least 10 fiber cores.

12 . The method of claim 11 wherein the array of optical fibers comprises at least 50 fiber cores.

13 . The method of claim 12 wherein the array of optical fibers comprises at least 100 fiber cores.

14 . The method of claim 1 wherein the optical subassembly comprises a half wave plate, and the active alignment process comprises projecting light from the array of optical fibers through the first lens array, the beam displacer, the half wave plate, and the second lens array to the at least one vertical-coupling element.

15 . The method of claim 1 wherein the optical subassembly comprises a spacer block disposed between the first lens array and the second lens array along an optical path, and the active alignment process comprises projecting light from the array of optical fibers through the first lens array, the spacer block, and the second lens array to the at least one vertical-coupling element.

16 . The method of claim 15 wherein the optical subassembly comprises a half wave plate, and the active alignment process comprises projecting light from the array of optical fibers through the first lens array, the spacer block, the half wave plate, and the second lens array to the at least one vertical-coupling element.

17 . The method of claim 1 wherein the fiber connector comprises a third lens array, and the active alignment process comprises projecting light from the array of optical fibers through the third lens array, including passing light from at least one of the optical fibers through a corresponding lens in the third lens array to a corresponding vertical-coupling element.

18 . The method of claim 17 wherein the active alignment process comprises projecting light from the array of optical fibers through the third lens array, the first lens array, and the second lens array to the at least one vertical-coupling element.

19 . The method of claim 18 wherein the active alignment process comprises projecting light from the array of optical fibers through the third lens array, the first lens array, the beam displacer, and the second lens array to the at least one vertical-coupling element.

20 . The method of claim 19 wherein the optical subassembly comprises a half wave plate, and the active alignment process comprises projecting light from the array of optical fibers through the third lens array, the first lens array, the beam displacer, the half wave plate, and the second lens array to the at least one vertical-coupling element.

21 . The method of claim 18 wherein the optical subassembly comprises a spacer block disposed between the third lens array and the second lens array along an optical path, and the active alignment process comprises projecting light from the array of optical fibers through the third lens array, the first lens array, the spacer block, and the second lens array to the at least one vertical-coupling element.

22 . The method of claim 21 wherein the optical subassembly comprises a half wave plate, and the active alignment process comprises projecting light from the array of optical fibers through the third lens array, the first lens array, the spacer block, the half wave plate, and the second lens array to the at least one vertical-coupling element.

23 . The method of claim 2 wherein the active alignment process comprises adjusting the position of the ferrule frame relative to the optical subassembly to maximize an overall efficiency of light transfer between the array of optical fibers and the photonic integrated circuit.

24 . The method of claim 1 wherein at least half of the ferrule frame by weight is made of at least one of glass, metal, or plastic.

25 . The method of claim 1 wherein the ferrule frame comprises a material that is transparent or semi-transparent to ultra-violet (UV) light, and securely connecting the ferrule frame to the optical subassembly comprises attaching the ferrule frame to the optical subassembly using an UV-curing adhesive.

26 . The method of claim 3 wherein adjusting the position of the ferrule frame relative to the optical subassembly comprises adjusting the position of the ferrule frame along a plane substantially parallel to the main surface of the photonic integrated circuit.

27 . The method of claim 26 wherein adjusting the position of the ferrule frame along the plane substantially parallel to the main surface of the photonic integrated circuit comprises at least one of (i) adjusting the position of the ferrule frame along an x-axis relative to the main surface of the photonic integrated circuit, (ii) adjusting the position of the ferrule frame along a y-axis relative to the main surface of the photonic integrated circuit, or (iii) rotating the ferrule frame about a z-axis relative to the main surface of the photonic integrated circuit;

wherein the x-and y-axes are substantially parallel to the main surface of the photonic integrated circuit, and the z-axis is substantially perpendicular to the main surface of the photonic integrated circuit.

28 . The method of claim 3 wherein adjusting the position of the ferrule frame relative to the optical subassembly comprises adjusting a distance of an end of the fiber connector relative to the optical subassembly.

29 . The method of claim 3 wherein adjusting the position of the ferrule frame relative to the optical subassembly comprises adjusting a tilt angle of an end surface of the fiber connector relative to the optical subassembly.

30 . The method of claim 1 wherein aligning the ferrule frame to the optical subassembly comprises aligning the ferrule frame to the optical subassembly with a precision of at least 10 um accuracy.

31 . The method of claim 30 wherein aligning the ferrule frame to the optical subassembly comprises aligning the ferrule frame to the optical subassembly with a precision of at least 1 um accuracy.

32 . The method of claim 31 wherein aligning the ferrule frame to the optical subassembly comprises aligning the ferrule frame to the optical subassembly with a precision of at least 0.1 um accuracy.

33 . The method of claim 1 , wherein each of the vertical-coupling elements comprises at least one of a single-polarization vertical grating coupler, a turning mirror, a polarization-diversity vertical grating coupler, a vertical cavity surface emitting laser, a surface-normal modulator, or a photodiode.

34 . The method of claim 1 wherein the beam displacer comprises a polarization-dependent optical element.

35 . The method of claim 1 in which the optical subassembly comprises a turning mirror that turns a first optical path between an optical fiber and a corresponding vertical-coupling element,

wherein the first optical path comprises a first optical path segment and a second optical path segment, the first optical path segment is between the vertical-coupling element and a reflecting surface of the turning mirror, the second optical path segment is between the reflecting surface of the turning mirror and the optical fiber, the second optical path segment is at an angle θ1 relative to the first optical path segment, and θ1 is in a range from 20° to 160°.

36 . The method of claim 35 in which θ1 is in a range from 45° to 110°.

37 . The method of claim 36 in which θ1 is in a range from 80° to 100°.

38 . The method of claim 37 in which after the ferrule frame is securely connected to the optical subassembly, the ferrule frame is oriented such that when the fiber connector is removably connected to the ferrule frame, at least some of the array of optical fibers output light beams along directions that are substantially parallel to the main surface of the photonic integrated circuit, the output light beams travel at an angle θ2 relative to the main surface of the photonic integrated circuit, and 0°≤θ2≤10°.

39 . The method of claim 35 in which the optical subassembly comprises a beam displacement element disposed between the turning mirror and the ferrule frame.

40 . The method of claim 35 in which the optical subassembly comprises a lens array disposed between the turning mirror and the photonic integrated circuit.

41 . The method of claim 1 , comprising using a computer to control a machine to align the ferrule frame to the optical subassembly using the active alignment process.

42 . The method of claim 1 wherein attaching the optical subassembly to the photonic integrated circuit comprises attaching the optical subassembly to a top side of the photonic integrated circuit;

wherein the method comprises attaching a bottom side of the photonic integrated circuit to a substrate or circuit board.

43 . The method of claim 1 wherein securely connecting the ferrule frame directly to the optical subassembly comprises securely connecting the ferrule frame directly to an upper portion of the optical subassembly;

wherein attaching the optical subassembly to the photonic integrated circuit comprises securely connecting a lower portion of the optical subassembly directly to a top side of the photonic integrated circuit.

44 . The method of claim 1 wherein securely connecting the ferrule frame directly to the optical subassembly comprises applying glue or a bonding material between the ferrule frame and the optical subassembly to securely connect the ferrule frame directly to the optical subassembly.

45 . A method comprising:

providing a photonic integrated circuit including a plurality of vertical-coupling elements disposed along a main surface of the photonic integrated circuit;

attaching an optical subassembly to the photonic integrated circuit to form a first module;

removably connecting a fiber connector to a ferrule frame, wherein the fiber connector is attached to an array of optical fibers;

aligning the ferrule frame to the first module using an active alignment process; and

securely connecting the ferrule frame directly to the first module after the alignment process;

wherein the optical subassembly comprises a first lens array, a second lens array, and a beam displacer, and the active alignment process comprises projecting light from the array of optical fibers through the first lens array, the beam displacer, and the second lens array to the plurality of vertical-coupling elements, including passing light from at least one of the optical fibers through a corresponding lens to a corresponding vertical-coupling element.

46 . The method of claim 45 wherein aligning the ferrule frame to the first module comprises aligning the ferrule frame to the optical subassembly using the alignment process.

47 . The method of claim 46 wherein securely connecting the ferrule frame directly to the first module comprises securely connecting the ferrule frame directly to the optical subassembly after the alignment process.

48 . The method of claim 47 wherein attaching the optical subassembly to the photonic integrated circuit comprises securely connecting a first portion of the optical subassembly directly to the photonic integrated circuit, and

wherein securely connecting the ferrule frame directly to the first module comprises securely connecting the ferrule frame directly to a second portion of the optical subassembly.

49 . The method of claim 45 wherein securely connecting the ferrule frame directly to the first module comprises applying glue or a bonding material between the ferrule frame and the first module to securely connect the ferrule frame directly to the first module.

50 . The method of claim 45 wherein the active alignment process includes transmitting light between at least one optical fiber and the photonic integrated circuit.

51 . The method of claim 50 wherein the active alignment process comprises:

transferring light between at least one optical fiber in the array of optical fibers and the photonic integrated circuit through the optical subassembly and at least one of the vertical-coupling elements, and

adjusting a position of the ferrule frame relative to the first module based on at least one characteristic of the light transferred between the at least one optical fiber and the photonic integrated circuit.

52 . The method of claim 51 wherein the ferrule frame is designed to enable the array of optical fibers to be removably attached to the ferrule frame and aligned to optimize an efficiency of light transfer between the photonic integrated circuit and the array of optical fibers.

53 . A method comprising:

providing a photonic integrated circuit including a plurality of vertical-coupling elements disposed along a main surface of the photonic integrated circuit;

attaching an optical subassembly to the photonic integrated circuit;

removably connecting a fiber connector to a ferrule frame, wherein the fiber connector is attached to an array of optical fibers;

aligning the ferrule frame to the optical subassembly using an active alignment process; and

securely connecting the ferrule frame directly to the optical subassembly after the alignment process;

wherein the optical subassembly comprises a first lens array, and the active alignment process comprises projecting light from the array of optical fibers through the first lens array, including passing light from at least one of the optical fibers through a corresponding lens to a corresponding vertical-coupling element;

wherein the optical subassembly comprises a second lens array, and the active alignment process comprises projecting light from the array of optical fibers through the first lens array and the second lens array to the at least one vertical-coupling element;

wherein the optical subassembly comprises a spacer block disposed between the first lens array and the second lens array along an optical path, and the active alignment process comprises projecting light from the array of optical fibers through the first lens array, the spacer block, and the second lens array to the at least one vertical-coupling element;

wherein the optical subassembly comprises a half wave plate, and the active alignment process comprises projecting light from the array of optical fibers through the first lens array, the spacer block, the half wave plate, and the second lens array to the at least one vertical-coupling element.

54 . A method comprising:

providing a photonic integrated circuit including a plurality of vertical-coupling elements disposed along a main surface of the photonic integrated circuit;

attaching an optical subassembly to the photonic integrated circuit;

removably connecting a fiber connector to a ferrule frame, wherein the fiber connector is attached to an array of optical fibers;

aligning the ferrule frame to the optical subassembly using an active alignment process; and

securely connecting the ferrule frame directly to the optical subassembly after the alignment process;

wherein the fiber connector comprises a first lens array, and the active alignment process comprises projecting light from the array of optical fibers through the first lens array, including passing light from at least one of the optical fibers through a corresponding lens to a corresponding vertical-coupling element;

wherein the optical subassembly comprises a second lens array and a beam displacer, and the active alignment process comprises projecting light from the array of optical fibers through the first lens array, the beam displacer, and the second lens array to the at least one vertical-coupling element.

55 . The method of claim 54 wherein the optical subassembly comprises a half wave plate, and the active alignment process comprises projecting light from the array of optical fibers through the first lens array, the beam displacer, the half wave plate, and the second lens array to the at least one vertical-coupling element.

56 . A method comprising:

providing a photonic integrated circuit including a plurality of vertical-coupling elements disposed along a main surface of the photonic integrated circuit;

attaching an optical subassembly to the photonic integrated circuit;

removably connecting a fiber connector to a ferrule frame, wherein the fiber connector is attached to an array of optical fibers;

aligning the ferrule frame to the optical subassembly using an active alignment process; and

securely connecting the ferrule frame directly to the optical subassembly after the alignment process;

wherein the fiber connector comprises a first lens array, and the active alignment process comprises projecting light from the array of optical fibers through the first lens array, including passing light from at least one of the optical fibers through a corresponding lens to a corresponding vertical-coupling element;

wherein the optical subassembly comprises a second lens array, and the active alignment process comprises projecting light from the array of optical fibers through the first lens array and the second lens array to the at least one vertical-coupling element;

wherein the optical subassembly comprises a spacer block disposed between the first lens array and the second lens array along an optical path, the optical subassembly further comprises a half wave plate, and the active alignment process comprises projecting light from the array of optical fibers through the first lens array, the spacer block, the half wave plate, and the second lens array to the at least one vertical-coupling element.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Feb 10, 2026
From: NUBIS COMMUNICATIONS, INC.
To: CIENA CORPORATION
Reel/Frame 073748/0292 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Feb 23, 2023
From: GILES, CLINTON RANDY; WINZER, PETER JOHANNES; ZHANG, RON; PUPALAIKIS, PETER JAMES; ELSINGER, LUKAS
To: NUBIS COMMUNICATIONS, INC.
Reel/Frame 062790/0281 →
Continuity (17)
Continuation In Part 17693040 · Mar 11, 2022
Provisional Application 63316551 · Mar 4, 2022
Provisional Application 63272025 · Oct 26, 2021
Provisional Application 63245559 · Sep 17, 2021
Provisional Application 63245005 · Sep 16, 2021
Provisional Application 63245011 · Sep 16, 2021
Provisional Application 63225779 · Jul 26, 2021
Provisional Application 63223685 · Jul 20, 2021
Provisional Application 63212013 · Jun 17, 2021
Provisional Application 63210437 · Jun 14, 2021
Provisional Application 63208759 · Jun 9, 2021
Provisional Application 63192852 · May 25, 2021
Provisional Application 63178501 · Apr 22, 2021
Provisional Application 63175021 · Apr 14, 2021
Provisional Application 63173253 · Apr 9, 2021
Provisional Application 63159768 · Mar 11, 2021
Related Publication 20220404566A1 · Dec 22, 2022
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