Optical Coupling Structure for Micro LED Arrays
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Solution Overview
Problem
Current technologies face challenges in achieving high optical coupling efficiency between Micro LED arrays and optical fibers, which is essential for efficient signal transmission in optical communication systems.
Innovation Solution
The proposed optical coupling structure involves a stacked configuration of an alignment layer, a growth substrate, and an optical functional layer, with through holes and an embedding structure that aligns and connects the Micro LED array with the optical fiber input end, enhancing stability and coupling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional coupling methods are used for Micro LED array to optical fiber, then the device complexity is reduced, but the optical coupling efficiency deteriorates
Solution Approach 1:
The coupling structure is divided into multiple functional layers: a first substrate, an alignment layer with second through holes, and a second substrate with first through holes. This segmentation allows each layer to perform its specific function (support, alignment, light transmission) independently, achieving high coupling efficiency while maintaining manageable complexity through modular design
Solution Approach 2:
The alignment layer acts as an intermediary component between the first substrate and the second substrate. It provides the second through holes that align with the first through holes, serving as a mediator to achieve precise optical alignment without requiring direct complex coupling between the LED array and optical fiber, thus improving coupling efficiency while adding only one intermediate layer
2Loss of energy
If precise alignment is achieved between optical functional layer and optical fiber, then optical coupling efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The alignment layer is prepared in advance with second through holes that are pre-aligned with the first through holes in the second substrate. This preliminary alignment action is performed before the final assembly, allowing the optical functional layer and optical fiber to be automatically aligned when the layers are stacked, thereby achieving high coupling efficiency without requiring extremely high precision in the final assembly step
Solution Approach 2:
The alignment problem is shifted from the lateral (horizontal) dimension to the vertical dimension. By creating through holes that extend vertically through multiple layers with precise lateral positioning in the alignment layer, the alignment tolerance in the lateral dimension is effectively increased, making manufacturing more feasible while maintaining high optical coupling efficiency
3Use of energy by moving object
If Micro LED is used as light source instead of semiconductor laser, then power consumption is reduced and reliability is improved, but optical coupling efficiency deteriorates due to lack of mature coupling schemes
Solution Approach 1:
The coupling structure designed with the alignment layer and stacked substrates serves as a universal solution that can be applied to various Micro LED array configurations and optical fiber types. This multi-functional design enables the structure to accommodate different Micro LED sizes, arrangements, and optical fiber specifications, making it feasible to use Micro LEDs as a universal low-power light source replacement for semiconductor lasers across different applications
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 solution improves the optical coupling efficiency by aligning the optical functional layer with the optical fiber input end, ensuring that light emitted from the Micro LED array directly enters the optical fiber, thereby enhancing the reliability and performance of optical communication systems.
Implementation Method 1
a growth substrate and an optical functional layer which are stacked sequentially, the growth substrate being used for epitaxially manufacturing the optical functional layer
Data Source
AI summary
An optical coupling structure includes an alignment layer, a growth substrate and an optical functional layer, the growth substrate being used for epitaxially manufacturing the optical functional layer, and the optical functional layer being aligned with a first through hole in the growth substrate; an optical fiber input end disposed in a second through hole in the alignment layer for improving stability of the optical fiber input end; and an embedding structure used to penetrate through the first and second through holes, which may not only clamp and fix the alignment layer and the growth substrate, effectively improving overall stability of the optical coupling structure, but also align the optical functional layer with the optical fiber input end, and therefore, light emitting from the optical functional layer directly enters the optical fiber input end through the first and second through holes, improving an optical coupling efficiency.