A Stamped Mirror to Connect Optical Fibers to Tiny Light Chips

This patent describes a method to precisely connect a standard optical fiber to a tiny light-based computer chip (a photonic integrated circuit) using a specially shaped, stamped mirror that redirects and reshapes the light.

What it covers

The patent describes an optical coupling that uses a "stamped optical bench" with a "structured reflective surface" (a mirror) to connect a single-mode optical fiber to a grating coupler on a photonic integrated circuit (PIC). This mirror "turns light transmitted between the grating coupler and the optical fiber" (Claim 1). Crucially, the mirror's "reflective surface profile" is shaped to "reshape the light" (Claim 1) to perfectly match the light coming from the fiber to the grating coupler's "design angle." For example, it can make light from a "flat polished optical fiber" look like it came from an "angled polished optical fiber" (Claim 2), which many existing grating couplers are designed for. The entire "optical bench" and the "fiber alignment structure" are made at the same time by "precision stamping a malleable metal body" (Claim 3).

What it doesn't cover

• —Does not cover systems that use a separate "refractive optical element" (like a lens) between the fiber and the mirror to reshape the light (Claims 4, 5, 6).
• —Does not cover systems where the mirror is not "stamped" or where the fiber alignment structure is not formed "integrally/simultaneously" with the mirror (Claim 3).
• —Does not cover using multi-mode optical fibers; it specifically claims a "single-mode fiber" (Claim 1).
• —Does not cover reflective surfaces that are not "three-dimensional concave reflective ellipsoidal" (Claim 1).

The clever bit

The clever bit is using a single, precision-stamped metal part that acts as both a mirror and an alignment structure. This mirror is not just for redirecting light, but its specific "three-dimensional concave reflective ellipsoidal surface profile" actively reshapes the light beam to perfectly match the receiving component, all without needing separate lenses.

Why it matters

Connecting optical fibers to photonic integrated circuits (PICs) is a major challenge in modern technology. PICs are becoming central to high-speed data communication and computing. This patent offers a manufacturing-friendly way to achieve precise optical alignment, which is critical for reliable and efficient light transmission in these systems. It addresses a bottleneck in packaging and integration.

Real-world examples

• 1.High-speed optical transceivers
• 2.Data center interconnects
• 3.Telecommunications equipment
• 4.Optical sensors