Bragg Grating Mounting Structure for Laser Output Stabilization
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Solution Overview
Problem
Current methods for mass-producing optical elements with optical waveguides and fine patterns result in deteriorated optical action and reduced laser output due to scattering and high manufacturing costs, particularly with sub-wavelength grating structures.
Innovation Solution
A method involving the formation of Bragg gratings on a laminate with a mounting substrate, clad layer, and optical material layer, followed by etching and mask formation to shape the grating elements, which reduces pattern size and enhances mirror-like end faces for efficient light propagation and reduced reflectance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sub-wavelength grating structures are used for optical waveguides, then optical action is enhanced, but manufacturing cost increases and optical action deteriorates due to scattering
Solution Approach 1:
The patent changes the grating period parameter to be equal to or larger than the wavelength of light in the optical waveguide, transitioning from sub-wavelength to wavelength-scale gratings. This parameter change maintains optical functionality while enabling simpler, more cost-effective manufacturing processes that avoid the scattering issues associated with sub-wavelength structures.
2Reliability
If sub-wavelength grating structures are used, then optical action is enhanced, but laser output decreases due to scattering
Solution Approach 1:
By changing the grating period parameter from sub-wavelength to wavelength-scale dimensions, the patent eliminates the scattering mechanism that reduces laser output. The new parameter regime maintains the desired optical action while preserving high laser output by avoiding harmful scattering effects.
3Productivity
If optical elements are mass-produced on wafer, then productivity increases, but manufacturing precision decreases due to optical action deterioration
Solution Approach 1:
The patent changes the grating period from sub-wavelength to wavelength-scale dimensions, which makes the optical patterns more robust against manufacturing variations. This parameter change allows mass-production on wafer while maintaining optical performance, as the larger features are less sensitive to precision requirements compared to sub-wavelength structures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach achieves high-efficiency light combination and recombination with semiconductor lasers or optical fibers, stabilizing laser output and reducing manufacturing costs by forming grating elements with optimized pattern sizes and surface finishes.
Implementation Method 1
forming a plurality of Bragg gratings at predetermined locations of a laminate comprising a mounting substrate, a clad layer provided on the mounting substrate and an optical material layer provided on the clad layer
Implementation Method 2
etching the optical material layer and the clad layer to shape an end face of each of the grating elements
Data Source
AI summary
A plurality of Bragg gratings are formed at predetermined locations of a laminate including a mounting substrate, a clad layer provided on the mounting substrate and an optical material layer provided on the clad layer. Optical waveguides are formed each including at least each of the Bragg gratings. Masks are formed each covering a region corresponding to each of the grating elements on the optical material layer. The optical material layer and clad layer are etched to shape an end face of each of the grating elements.