A Sealed, Stamped Metal Assembly for Guiding Light in Fiber Optics

This patent describes a tiny, sealed optical assembly that uses precisely shaped metal parts and mirrors to guide light signals between a fiber optic cable and an electronic light-emitting or light-sensing device without needing lenses between the main mirrors.

What it covers

This patent details a "hermetic optical subassembly" designed to precisely direct light signals. It includes a first metal part, called an "optical bench," that holds an optical fiber and has a tiny mirror. A second metal optical bench also has a mirror. Between these two mirrors, light travels without passing through any lenses or prisms. A "carrier" holds a "photonic device," which is something that either creates light (like a laser) or detects it (like a photodetector). All these parts are carefully aligned so light goes from the fiber, bounces off the first mirror, then the second mirror, and finally reaches the photonic device, or vice-versa. The entire assembly is sealed tightly, making it "hermetic" to protect the delicate components. The metal benches and their mirrors are made by "stamping" malleable metal, which allows for very precise shapes. For example, it could connect a laser to a fiber optic cable for high-speed internet.

What it doesn't cover

• —Does not cover optical assemblies that use lenses or prisms directly between the two main mirrors to guide the light signal.
• —Does not cover assemblies where the optical benches or mirrors are formed by methods other than stamping a malleable metal material.
• —Does not cover non-hermetically sealed optical components, meaning it must be tightly sealed against outside elements.
• —Does not cover direct fiber-to-device coupling without the use of two intermediate mirrors to redirect the optical path.
• —Does not cover systems where the first optical bench, second optical bench, and carrier are not coupled together to form a single package.

The clever bit

The clever part is using precisely stamped malleable metal to form the optical benches and their mirrors. This allows for very accurate alignment of light paths in a compact, robust, and hermetically sealed package, all without needing complex lenses between the main mirrors.

Why it matters

This technology is important for creating reliable and compact optical communication components. By precisely aligning and sealing these tiny light-guiding parts, it helps ensure that high-speed data signals can travel long distances without degradation. This is crucial for data centers, telecommunications networks, and other applications where optical signals are used to transmit vast amounts of information quickly and dependably. The robust, sealed design protects sensitive components from environmental damage.

Real-world examples

• 1.Fiber optic transceivers in data centers
• 2.Optical modules for 5G telecommunications infrastructure
• 3.High-speed optical interconnects for supercomputers
• 4.Sensors in harsh industrial environments
• 5.Components for long-haul fiber optic networks