Laser Bar Alignment Trenches for Vertical Positioning
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Solution Overview
Problem
The challenge in optical systems is achieving accurate vertical alignment between lasers and optical devices, as existing methods rely on less precise techniques such as etching, leading to inconsistencies in the alignment of waveguides and lasers.
Innovation Solution
The optical system incorporates a laser bar with alignment trenches containing secondary stops made of layers with different compositions, which extend into corresponding stops on the optical device, allowing for precise control of the laser's vertical position by adjusting the thickness of the alignment layer, ensuring accurate alignment with the waveguides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If etching techniques are used for vertical alignment, then the manufacturing process is simple, but the alignment precision is insufficient
Solution Approach 1:
The patent applies preliminary action by pre-forming stops on the optical device and secondary stops in the alignment trenches before final assembly. These stops and secondary stops are positioned at predetermined locations and heights, enabling accurate vertical alignment to be achieved simply by placing the laser bar onto the optical device without requiring complex real-time adjustment or high-precision etching during assembly.
Solution Approach 2:
The patent uses stops and secondary stops as intermediary elements that mediate the alignment between the laser bar and optical device. The stops extend upward from the optical device while secondary stops extend into alignment trenches, creating mechanical interfaces that automatically establish the correct vertical position when the components are assembled, thereby achieving high alignment precision without complex procedures.
2Manufacturing precision
If alignment marks are used for horizontal alignment, then the alignment process is simple, but the vertical alignment quality is poor
Solution Approach 1:
The patent transitions from two-dimensional alignment mark matching to three-dimensional mechanical interlocking by introducing stops with specific heights and secondary stops in trenches. This dimensional change allows vertical alignment to be controlled by the physical geometry of the stops rather than relying on less accurate planar alignment marks, achieving superior vertical alignment quality while maintaining ease of manufacture through straightforward assembly.
3Manufacturing precision
If the alignment layer thickness is increased, then the vertical alignment precision is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by utilizing the thickness of the alignment layer as a controllable parameter. By carefully selecting and controlling the thickness of the alignment layer (which forms the secondary stops), the vertical position of the laser relative to the waveguide can be precisely adjusted. This allows high alignment precision to be achieved through a single critical parameter (layer thickness) rather than through complex multi-parameter optimization.
Data Source
AI summary
An optical system includes an optical device having waveguides defined in a first light transmitting medium. The optical device includes stops extending upward from a laser platform. The system also includes a laser bar having a plurality of lasers. The laser bar is positioned on the platform such that each laser is aligned with one of the waveguides. The laser bar includes alignment trenches that each includes a secondary stop extending upward from a bottom of the alignment trench. The secondary stop includes layers of material having different composition. The stops each extend into an alignment trenches such that each stop contacts one of the secondary stops.