Optical Coupling Component with Reflective Curved Surface
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Solution Overview
Problem
Current methods for producing optical couplers result in high light losses due to inaccurate positioning of waveguides and coupling elements, leading to inefficient coupling and increased reject rates, especially when used in combination with waveguide structures on substrates.
Innovation Solution
A method where a coupling element with a reflective curved surface is applied to a substrate, allowing for precise measurement and alignment, enabling the fabrication of a waveguide structure that optimally interacts with the coupling element for low-loss light deflection and collimation, separate from the waveguide structure production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If optical components are applied to substrate and waveguide structure is produced by direct writing, then waveguide structure can be manufactured, but positioning accuracy between waveguide and optical component deteriorates leading to high light losses
Solution Approach 1:
The optical component is mounted on the substrate before producing the waveguide structure. By performing the mounting operation first, the system establishes a fixed reference point that guides subsequent waveguide fabrication, ensuring accurate positioning without requiring high-precision alignment during the waveguide writing process.
Solution Approach 2:
A marking structure is introduced as an intermediary element between the optical component and the waveguide structure. The marking structure serves as a reference framework that facilitates precise positioning of the waveguide relative to the optical component, acting as a mediator that translates the position of the optical component into actionable alignment information for waveguide fabrication.
2Reliability
If positioning accuracy is improved by measuring and aligning optical components, then coupling efficiency increases, but production complexity and reject rate increase
Solution Approach 1:
The marking structure is created during the waveguide layer formation process itself, rather than as a separate post-processing step. This integration eliminates additional alignment operations and reduces production complexity while maintaining high coupling efficiency, as the marking information is inherently tied to the waveguide structure.
Solution Approach 2:
The system uses itself to create alignment references. The waveguide layer and marking structure are formed together in the same photolithographic process, allowing the structure to self-generate its own positioning information without requiring external measurement and alignment equipment, thereby simplifying the production process.
3Adaptability or versatility
If optical component position is determined after application, then adaptability to positioning variations is improved, but waveguide structure alignment precision deteriorates
Solution Approach 1:
The marking structure provides immediate feedback information about the optical component's position directly to the waveguide fabrication process. By encoding position information in the marking structure that is created during waveguide layer formation, the system translates positional variations into actionable alignment data, maintaining precision while accommodating flexibility in component placement.
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 reduces light attenuation, enhances coupling efficiency, and allows for mass production of standardized optical components suitable for various applications, including those with electrical and optical functions on printed circuit boards.
Implementation Method 1
The coupling element has a reflective curved surface for simultaneously changing the direction of propagation and the shape of wavefronts of light propagating between the waveguide structure and the optical component
Implementation Method 2
a layer of liquid, light-sensitive material, for example a UV-curable polymer, is applied to the substrate. The layer is written directly using an incoherent light source to form waveguide structures. Direct writing selectively exposes and hardens the photosensitive material.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The component has a wave guide structure (4), and a coupling unit (3) for optical coupling of the structure with another optical component. The unit has a reflective curved surface (31) that is provided for changing propagation direction and the form of wave fronts of light, which is propagated between the structure and the latter component. The structure and the unit are installed on a common substrate (2). An independent claim is also included for a method for manufacturing an optical component.