Composite Substrate for Photonic Crystal Element
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Solution Overview
Problem
Existing composite substrates for photonic crystal elements face issues such as peeling and optical loss due to adhesive deterioration and the formation of amorphous layers, which affect the electro-optical effect and drive voltage reduction.
Innovation Solution
A composite substrate is developed with an electro-optical crystal substrate and a support substrate integrated through an optical loss-suppressing and cavity-processing layer, which prevents peeling and amorphous layer formation, using direct joining without adhesives and incorporating additional layers like peeling-preventing, joining, and sacrificial layers for enhanced integration and optical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is used to join electro-optical crystal substrate and support substrate, then joining is achieved, but peeling occurs over time due to adhesive deterioration
Solution Approach 1:
The invention removes the adhesive layer from the joining structure, eliminating the source of peeling and deterioration. Direct joining between the electro-optical crystal substrate and support substrate is achieved through surface treatment and controlled bonding processes, extracting the problematic intermediate adhesive material from the system.
Solution Approach 2:
An amorphous layer is intentionally formed as an intermediary between the electro-optical crystal substrate and support substrate during direct joining. This controlled amorphous layer acts as a mediator that facilitates bonding while maintaining optical transparency and preventing peeling, replacing the problematic adhesive with a functionally superior intermediate layer.
2Reliability
If direct joining is used without adhesive, then peeling is prevented, but amorphous layer formation causes optical loss and deteriorates electro-optical effect
Solution Approach 1:
The invention applies local quality control by treating only specific regions of the substrate surfaces. The amorphous layer is formed selectively at the joining interface where it is needed for bonding, while the bulk optical regions maintain their original crystalline quality and optical properties. This localized approach ensures peeling resistance at the interface without compromising overall optical performance.
Solution Approach 2:
The invention controls the physical and chemical parameters of the amorphous layer, including its thickness, composition, and optical density. By adjusting these parameters, the amorphous layer achieves optimal balance between providing sufficient bonding strength to prevent peeling and maintaining adequate optical transparency to minimize light absorption and scattering losses.
3Strength
If amorphous layer is formed during direct joining, then joining is achieved, but interface becomes non-flat causing light scattering
Solution Approach 1:
The invention performs preliminary surface treatment and preparation before the actual joining process. Surface flatness is ensured through polishing, planarization, or other preprocessing steps applied to both substrates before they are joined. This preliminary action guarantees that the interface maintains adequate flatness even after the amorphous layer forms during bonding.
Solution Approach 2:
The invention creates a composite structure at the interface consisting of the amorphous layer combined with surface treatment layers or coating materials. This composite interface structure combines the bonding benefits of the amorphous layer with the flatness-providing properties of treated surface layers, achieving both strong joining and adequate interface flatness simultaneously.
Data Source
AI summary
A composite substrate (100) for a photonic crystal element includes: an electro-optical crystal substrate (10) having an electro-optical effect; an optical loss-suppressing and cavity-processing layer (20) arranged on one surface of the electro-optical crystal substrate (10); and a support substrate (30) integrated with the electro-optical crystal substrate (10) through the optical loss-suppressing and cavity-processing layer (20).