Optical Modulator Electrode Extensions for Stable Layer Formation

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Solution Overview

Problem

Existing optical modulators face challenges in stably modulating light due to issues such as dielectric breakdown and uneven opening densities in the modulation layer.

Innovation Solution

The optical modulator features a conductive portion with a pattern structure comprising alternating first and second electrode portions and extension portions, formed using electro-optic polymer, which stabilizes the modulation process by securing intervals and preventing abnormal electric field concentration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the pattern structure portion is formed by imprint lithography without extension portions, then the manufacturing process is simpler, but the functional portion cannot be formed stably and dielectric breakdown occurs

Engineering Contradiction:
Improvemanufacturing process simplicityVSAvoidstability of light modulation
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The extension portions are designed to extend from the base portions toward the opposing pattern portions, preliminarily establishing proper spacing and preventing dielectric breakdown before the modulation function is activated. This preliminary structural arrangement ensures stable formation of the functional portion during imprint lithography.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The extension portions act as intermediary structures between the base portions and the pattern portions, mediating the electric field distribution and preventing direct contact that would cause dielectric breakdown. These extension portions stabilize the functional portion formation while maintaining manufacturing feasibility.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Reliability

If the first extension portions and second extension portions are provided, then the intervals are secured and dielectric breakdown is suppressed, but the device structure becomes more complex

Engineering Contradiction:
Improvestability of light modulationVSAvoidconductive portion structure
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The conductive portion is segmented into base portions, extension portions, and pattern portions, with each segment serving a specific function. The extension portions are segmented structures that extend from the base portions, creating a modular design that improves reliability while maintaining manufacturing feasibility through systematic segmentation.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The extension portions add a dimensional element to the conductive structure, extending in the thickness direction to create proper spacing. This dimensional addition prevents dielectric breakdown by establishing adequate intervals, transforming a two-dimensional pattern into a three-dimensional structured system.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

3Ease of manufacture

If the intervals between pattern portions and base portions are not secured, then the manufacturing process is simpler, but abnormal electric field concentration occurs causing dielectric breakdown

Engineering Contradiction:
Improvepattern formation simplicityVSAvoiddielectric breakdown
Core Design Contradiction:
Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The extension portions provide beforehand cushioning by pre-establishing adequate intervals between the base portions and pattern portions. This cushioning structure prevents abnormal electric field concentration and dielectric breakdown before they can occur, ensuring stable operation of the optical modulator.

Inventive Principle:
Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The extension portions, which add structural complexity, convert the potential harm of dielectric breakdown into a benefit by creating a protective intermediary structure. This transformation turns a reliability issue into a design feature that enhances overall device stability.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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 design allows for high-speed light modulation with stable formation of the modulation layer, reducing dielectric breakdown and ensuring consistent opening densities, thereby enhancing the modulator's stability and performance.

Implementation Method 1

a modulation layer which consists of an electro-optic polymer and is formed on the conductive pattern layer, and of which a refractive index varies due to application of an electric field

Methodology Applied
Scientific EffectElectro-optic effect: Electro-Optic Effects

Data Source

PatentUS20250277995A1Optical modulator and method for manufacturing optical modulator
Publication Date: 2025.09.04 HAMAMATSU PHOTONICS KK
  • US20250277995A1 patent drawing
  • US20250277995A1 patent drawing
  • US20250277995A1 patent drawing

AI summary

An optical modulator includes a substrate, a conductive portion, and a modulation layer. The conductive portion includes a first electrode portion and a second electrode portion. The first electrode portion includes a first base portion, and a first pattern portion extending from the first base portion in a first direction. The second electrode portion includes a second base portion facing the first base portion in the first direction, and a second pattern portion that extends from the second base portion in the first direction and is arranged alternately with the first pattern portion in a 10 second direction. The first electrode portion further includes a first extension portion extending from the first base portion toward the second pattern portion in the first direction, and the second electrode portion further includes a second extension portion extending from the second base portion toward the first pattern portion in the first direction.