Optical Interposer 45-Degree Dry-Etched Facet Alignment
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Solution Overview
Problem
Conventional fiber optic interposers with V-grooves suffer from non-optimal signal transmission due to light being reflected away from the optical fiber axis, and the process of depositing reflective coatings on fiber end faces is costly and time-consuming.
Innovation Solution
An interposer with a substrate featuring dry-etched facets, particularly a 45-degree facet for improved optical coupling, which reduces the air gap with the fiber or planar waveguide end face, and includes additional facets for enhanced alignment and coupling, eliminating the need for reflective coatings on the fiber end faces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional V-groove with 54.7-degree end face is used, then the optical fiber can be mechanically retained, but light is reflected away from the optical fiber axis causing non-optimal signal transmission
Solution Approach 1:
The patent changes the geometric parameters of the groove end face from the conventional 54.7-degree angle to a 45-degree angle. This parameter modification redirects the reflected light to align with the optical fiber axis, improving signal transmission performance while maintaining manufacturing feasibility through standard dry etching processes.
Solution Approach 2:
The patent replaces the need for complex multi-faceted mirror structures with a simpler 45-degree groove end face configuration. This substitution eliminates the requirement for precise metallic coating on multiple facets while achieving the same optical coupling function through the geometric configuration alone.
2Reliability
If metallic reflective coating is deposited on fiber end faces to improve optical coupling, then optical coupling efficiency is improved, but manufacturing cost and time increase
Solution Approach 1:
The patent extracts and eliminates the metallic reflective coating step from the manufacturing process. By using a 45-degree groove end face configuration, the patent achieves optimal optical coupling without requiring the deposition of reflective materials, thereby simplifying the manufacturing process and increasing production throughput.
Solution Approach 2:
The patent replaces expensive and time-consuming metallic coating processes with a simple geometric configuration that can be achieved through standard dry etching. This substitution uses a cost-effective manufacturing approach that maintains optical performance without the need for costly material deposition.
3Reliability
If multiple facets are created on the groove end face for optimal optical coupling, then optical performance is improved, but device complexity increases
Solution Approach 1:
The patent segments the groove structure into a simple 45-degree end face configuration rather than creating multiple complex facets. This segmentation approach achieves optimal optical coupling through a single, clean geometric feature, reducing structural complexity while maintaining high optical performance.
Solution Approach 2:
Instead of adding multiple facets to the groove end face to improve optical coupling, the patent inverts the approach by using a simple 45-degree configuration that inherently provides the desired optical performance. This inversion simplifies the structure while achieving the same functional goal.
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 achieves high-efficiency optical coupling between optical components and fibers or planar waveguides, facilitating passive alignment and reducing manufacturing costs while improving signal transmission performance.
Implementation Method 1
a first facet at the terminal end perpendicular to side walls, the facet having a first angle relative to the top planar surface... a reflective coating on the first facet
Implementation Method 2
at least one groove defined in the top planar surface and extending from an edge of the substrate to a terminal end, the groove having side walls and a first facet at the terminal end perpendicular to side walls, the facet having a first angle relative to the top planar surface, the first angle being about 45 degrees
Data Source
AI summary
A process for preparing a subassembly, the process comprising (a) defining the location of one or more grooves for receiving at least one polymer waveguide in a wafer, (b) etching the grooves into the wafer, each groove having sidewalls and a first facet at the terminal end perpendicular to the side walls, the first facet having a first angle relative to the top planar surface, (c) coating the first facet with a reflective material, and (d) disposing a fluid polymer waveguide precursor into each groove, and writing a core into the polymer material by directing at least one laser beam on the first facet by directing the laser beam into the top of the polymer material such that the beam reflects off of the first facet and down the interior of the polymer material to form the core in the polymer waveguide.