Optical Functional Integrated Unit with Segmented Pedestal Mounting
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Solution Overview
Problem
The integration of positive and passive optical devices with silicon waveguides is hindered by the need for a non-reflective coating on the end face of silicon waveguides, which is disrupted by the presence of steps in photonics devices, making it difficult to achieve even and durable coatings using vacuum vapor deposition.
Innovation Solution
An optical functional integrated unit is designed with a mounting board and separate pedestals for a positive optical device and a passive optical device, where the passive device includes a silicon waveguide, allowing for precise alignment and non-reflective coatings to be applied without the need for uneven surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a non-reflective coating is applied to the end face of silicon waveguide using vacuum vapor deposition, then the coating quality is improved, but the presence of steps in photonics devices disrupts the coating process and prevents even and durable coatings
Solution Approach 1:
The patent divides the integration process into separate stages: first mounting the silicon waveguide on a substrate, then adding the positive optical device in a subsequent step. This segmentation allows the non-reflective coating to be applied to the silicon waveguide end face before the positive optical device is mounted, avoiding the coating disruption caused by steps in integrated structures.
Solution Approach 2:
The non-reflective coating is applied in advance to the silicon waveguide end face before the positive optical device is mounted. This preliminary action ensures that the coating surface is flat and accessible to the vacuum vapor deposition process, eliminating the coating quality issues that would arise from subsequent step formation.
2Adaptability or versatility
If positive and passive optical devices are integrated in the same device, then device integration is improved, but coating process becomes disrupted and manufacturing complexity increases
Solution Approach 1:
The patent segments the device structure into a passive optical device (silicon waveguide) mounted on a substrate and a positive optical device mounted separately on the substrate. This segmentation enables the non-reflective coating to be applied to the silicon waveguide end face without disruption, while still achieving functional integration of both device types.
Solution Approach 2:
The substrate serves as an intermediary platform that holds both the passive optical device (silicon waveguide) and the positive optical device. This intermediary structure allows the two device types to be integrated functionally while maintaining separate mounting surfaces that are compatible with the vacuum vapor deposition coating process.
3Measurement precision
If steps are provided in photonics devices for mounting, then alignment capability is improved, but the end face becomes uneven and non-reflective coating cannot be applied evenly
Solution Approach 1:
The patent separates the alignment function from the coating surface by mounting the silicon waveguide on a substrate with steps for alignment, while the end face of the silicon waveguide itself remains flat and accessible for coating. This segmentation allows both alignment capability and coating flatness to be achieved simultaneously.
Solution Approach 2:
The patent moves the alignment function to a different dimension by providing steps on the substrate surface for mounting the silicon waveguide, while keeping the end face (coating surface) in a separate dimensional plane that remains flat and accessible. This dimensional separation allows alignment steps and flat coating surface to coexist without conflict.
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 configuration enables the effective integration of positive and passive optical devices with silicon waveguides, allowing for wavelength-tunable laser operations and reducing manufacturing time and costs by eliminating the need for complex surface preparation.
Implementation Method 1
it is impossible to provide the even and durable coating on the end part of the silicon waveguide by the vacuum vapor deposition
Data Source
AI summary
It is provided that an optical functional integrated unit and a method for manufacturing thereof in which a positive optical device and a passive optical device including a silicon waveguide can be readily integrated. An optical functional integrated unit includes a semiconductor optical amplifier, a photonics device, a mounting board, pedestals and. The pedestals and are provided on the mounting board. The semiconductor optical amplifier is mounted on the pedestal and outputs a light from an active layer. The photonics device is mounted on the pedestal. The photonics device includes silicon waveguide to which the light output from the semiconductor optical amplifier is guided.