# US 2023/0053498 A1 · Packaging structure and packaging method of edge couplers and fiber array

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- Number: US 2023/0053498 A1
- Document ID: US20230053498A1
- Status: Published application
- Kind: A1
- Application number: 17/889,434
- Filed: 2022-08-17
- Published: 2023-02-23
- Earliest claimed: 2021-08-17
- Assignees: Suteng Innovation Technology Co., Ltd.
- Applicants: Suteng Innovation Technology Co., Ltd.
- Inventors: Lin ZHU; Jing WANG; Ben NIU
- Web page: https://patentgrep.com/patent/US20230053498A1

## CPC

- G02B 6/4212: {the intermediate optical element being a coupling medium interposed therebetween, e.g. epoxy resin, refractive index matching material, index grease, matching liquid or gel}
- G02B 6/4243: {Mounting of the optical light guide into a groove (mounting optical light guides into a groove in general G02B6/3636)}
- G02B 6/43: Arrangements comprising a plurality of opto-electronic elements and associated optical interconnections
- G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS

## Abstract

A packaging structure and a packaging method of edge couplers and a fiber array are provided. The packaging structure includes a silicon substrate, an edge coupler, and a fiber array. Multiple edge couplers are arranged in a main body portion of the silicon substrate, and an end of the edge coupler extends to a step groove of the silicon substrate. At least a part of the cover of the fiber array is accommodated in the step groove. Multiple fibers in the fiber array correspondingly pass through multiple lead channels of the cover and are then coupled with the edge couplers in the step groove. The edge couplers butt the fibers in the fiber array. The cover is moved until a part of the cover is accommodated in the step groove, so that the fibers can be aligned with the edge couplers in the step groove.

## Claims

### Claim 1

A packaging structure of edge couplers and a fiber array, comprising:
a silicon substrate, having a main body portion and an edge portion connected to a side of the main body portion, wherein the main body portion and the edge portion form a step groove;
edge couplers, wherein a plurality of edge couplers are arranged in the main body portion, and an end of each of the edge couplers extends to the step groove; and
a fiber array, comprising a cover and a plurality of fibers,
wherein at least a part of the cover is accommodated in the step groove,
wherein the cover has a butting face facing the plurality of edge couplers and a plurality of lead channels that protrude through the cover and extend to the butting face, and
wherein the plurality of fibers correspondingly pass through the plurality of lead channels and are then coupled with the plurality of edge couplers at the butting face.

### Claim 2 (depends on 1)

The packaging structure of edge couplers and a fiber array according to claim 1, further comprising a refractive index matching layer,
wherein each of the edge couplers has a coupling edge, and extends until the coupling edge connects a surface of the step groove,
wherein each of the fibers comprises a fiber core and cladding around a periphery of the fiber core, the fiber core has a fiber edge for butting the coupling edge, and the fiber edge is flush with the butting face, and
wherein the refractive index matching layer is arranged between the surface of the step groove and the butting face, the refractive index matching layer covers the coupling edge and the fiber edge respectively, and the refractive index matching layer is configured to transmit light and reduce coupling loss between the edge couplers and the fibers.

### Claim 3 (depends on 2)

The packaging structure of edge couplers and a fiber array according to claim 2, wherein the step groove has a first step face and a second step face that are perpendicular to each other,
wherein the main body portion has a first surface connected to the first step face, the edge couplers are arranged on the first surface, and the refractive index matching layer extends to partially cover the edge couplers arranged within the first surface,
wherein the edge portion has a second surface connected to the second step face, the cover is located on a side on which the step groove and the second surface are located, and the cover has a first connection face that is opposite and spaced apart from the second surface, and
wherein the refractive index matching layer extends to fill a space between the second surface and the first connection face.

### Claim 4 (depends on 3)

The packaging structure of edge couplers and a fiber array according to claim 3, wherein the cover comprises a first cover plate and a second cover plate,
wherein the first connection face is located on the first cover plate, and the first cover plate further has a second connection face connected to the first connection face,
wherein the butting face is located on the second cover plate, the second cover plate has a third connection face connected to the butting face, and the third connection face is connected to the second connection face, and
wherein a plurality of lead grooves are formed on the third connection face in a one-to-one correspondence with the plurality of fibers, the lead grooves extend to the butting face, and the second connection face and side walls of the lead grooves jointly define the lead channels.

### Claim 5 (depends on 4)

The packaging structure of edge couplers and a fiber array according to claim 4, wherein the third connection face comprises a main portion and a groove portion enclosing the lead groove,
wherein the butting face and the main portion are flat and perpendicular to each other,
wherein ends of the main portion and the groove portion that are respectively connected to the butting face are accommodated in the step groove, and
wherein both the main portion and the groove portion are spaced apart from the surface of the step groove.

### Claim 6 (depends on 4)

The packaging structure of edge couplers and a fiber array according to claim 4, wherein the second cover plate extends toward a side on which the silicon substrate is located to form a reinforcing portion, and
wherein the reinforcing portion is located on a side of the butting face away from the third connection face, and the reinforcing portion is fixedly connected to the main body portion.

### Claim 7 (depends on 1)

The packaging structure of edge couplers and a fiber array according to claim 1, further comprising a bonding layer,
wherein the silicon substrate is fixedly connected to the cover by the bonding layer.

### Claim 8 (depends on 1)

The packaging structure of edge couplers and a fiber array according to claim 1, wherein each of the lead channels is a bar-shaped lead channel,
wherein each of the fibers has a first end and a second end that are opposite each other, and
wherein the first end is adjacent to the butting face, and the second end protrudes from the bar-shaped lead channel.

### Claim 9 (depends on 1)

The packaging structure of edge couplers and a fiber array according to claim 1, wherein the packaging structure has at least two groups of the edge couplers, the fibers, and the lead channels that are abreast arranged in a one-to-one correspondence manner,
wherein each of the edge couplers further comprises a loopback waveguide formed on the silicon substrate, and the loopback waveguide is connected to the two edge couplers at both ends, and
wherein each of the fibers is configured to receive light and direct the light to the each of the edge couplers.

### Claim 10

A packaging method of edge couplers and a fiber array, comprising:
moving a cover of a fiber array, so that a butting face of the cover is accommodated in a step groove of a silicon substrate, and after a plurality of fibers in the fiber array pass through a plurality of lead channels in the cover in a one-to-one correspondence manner;
coupling the plurality of fibers with a plurality of edge couplers arranged on the silicon substrate and extending to the step groove in a one-to-one correspondence manner;
connecting two of the edge couplers located at two ends, first selecting two of the fibers in the middle and emitting red light into the two fibers respectively, then emitting detection light into one of the two fibers located at the two ends, connecting the other fiber to an optical power meter, and reading an optical power value displayed on the optical power meter; and
moving the fiber array until the optical power value displayed on the optical power meter reaches its maximum, and fixedly connecting the cover to the silicon substrate.

### Claim 11 (depends on 10)

The packaging method of edge couplers and a fiber array according to claim 10, wherein the fiber array is moved, so that a fiber edge of each of the fibers is moved relative to a coupling edge of one of the edge couplers in the step groove,
wherein a reading of the optical power meter is read in real time until data displayed on the optical power meter reaches its maximum,
wherein a relative position of the silicon substrate and the fiber array is maintained unchanged, and
wherein a refractive index matching layer is arranged between a surface of the step groove and the butting face, to fixedly connect the cover to the silicon substrate.

### Claim 12 (depends on 11)

The packaging method of edge couplers and a fiber array according to claim 11, wherein a method of moving the fiber array so that the data displayed on the optical power meter reaches its maximum comprises:
filling a liquid adhesive for transmitting light in a space between the surface of the step groove and the butting face;
continuously moving the fiber array until the reading of the optical power meter reaches its maximum; and
curing the liquid adhesive, to form the refractive index matching layer.

### Claim 13 (depends on 12)

The packaging method of edge couplers and a fiber array according to claim 12, wherein after the liquid adhesive is filled in the space between the surface of the step groove and the butting face to increase the reading of the optical power meter, the fiber array is further moved until the reading of the optical power meter reaches its maximum.

### Claim 14 (depends on 12)

The packaging method of edge couplers and a fiber array according to claim 12, wherein a method for curing the liquid adhesive comprises:
changing a curing condition in a cascading manner, and
when it is observed that the reading of the optical power meter is unchanged or changes within a first value range, controlling the curing condition until the liquid adhesive is cured into the refractive index matching layer.

### Claim 15 (depends on 10)

The packaging method of edge couplers and a fiber array according to claim 10, wherein the cover extends toward a side on which the silicon substrate is located to form a reinforcing portion, and
wherein the reinforcing portion covers the step groove, and the reinforcing portion is connected to the silicon substrate.