Optical Module With Stacked Waveguide Layers And Prism
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Solution Overview
Problem
Conventional optical modules using PLC technology face challenges in miniaturization and high density due to the need for separate channels and alignment of laser and optical fibers, resulting in large planar space occupation and low I/O density.
Innovation Solution
The optical module design incorporates two waveguide layers in a perpendicular direction, utilizing a prism and filter to enable optical signal transmission and reflection between the layers, reducing the width of the optical channel and planar space, and improving I/O density by fully utilizing Z-direction space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If single fiber bidirectional mode is used with PLC technology, then optical channel integration is achieved, but receiving and transmitting channels must be fabricated simultaneously in the same plane requiring certain distance for LD and fiber assembly, resulting in large planar space occupation
Solution Approach 1:
The patent transitions from a two-dimensional planar fabrication approach to a three-dimensional stacked architecture. Multiple optical channels are arranged in different layers (first optical channel layer, second optical channel layer) stacked in the vertical direction, allowing optical signals to be transmitted between layers through vertical coupling structures. This dimensional change enables higher integration density while reducing planar space requirements.
2Adaptability or versatility
If receiving and transmitting optical channels are fabricated in the same plane, then bidirectional communication is enabled, but certain distance must be maintained for LD and optical fiber assembly, reducing I/O density
Solution Approach 1:
The patent separates receiving and transmitting optical channels into different vertical layers. The first optical channel layer contains receiving channels while the second optical channel layer contains transmitting channels. Vertical coupling structures enable optical signal transmission between layers, achieving bidirectional communication functionality while maximizing I/O density by eliminating the need for lateral spacing between transmitting and receiving components.
Solution Approach 2:
The optical channel system is segmented into multiple independent layers, with each layer dedicated to specific functions (receiving or transmitting). This segmentation allows independent optimization of each layer's layout and reduces interference between transmitting and receiving channels, thereby increasing overall I/O density while maintaining bidirectional communication capability.
3Ease of manufacture
If conventional TO packaging technology is used, then component assembly is achieved, but structural member limitations and processing precision constraints prevent further miniaturization
Solution Approach 1:
The patent merges multiple optical channels and their associated components into a unified stacked architecture. Multiple optical channels from different layers are integrated through shared coupling structures and common packaging substrates, reducing the number of separate structural members needed and enabling further miniaturization while maintaining ease of manufacture through standardized assembly processes.
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 effectively reduces the planar space occupied by the optical module, enhances I/O density, and improves the overall system density by allowing for more compact and efficient optical signal transmission and reception.
Implementation Method 1
the first reflective surface of the prism and the second reflective surface of the prism are aligned with the first waveguide layer and the second waveguide layer respectively; and a position among the filter, the prism, the first waveguide layer and the second substrate enables an optical signal input to the optical channel in the first waveguide layer to enter the optical channel in the second waveguide layer after being reflected by the prism
Implementation Method 2
an optical signal input to the optical channel in the second waveguide layer to enter the filter after being transmitted by the prism
Data Source
Figure 1
Figure 2
Figure 3~3a
AI summary
Embodiments of the present invention disclose an optical module manufacturing method, including: forming a first waveguide layer and a second waveguide layer on a first substrate and a second substrate respectively, or forming a first waveguide layer and a second waveguide layer on a first surface of the first substrate and a second surface of the first substrate respectively; disposing the first substrate on the second substrate; disposing a filter at an end of the first waveguide layer and the second waveguide layer, so that the filter is aligned with the second waveguide layer; and disposing a prism on the filter, so that a first reflective surface of the prism is aligned with the first waveguide layer, and the second reflective surface is aligned with the second waveguide layer. The embodiments of the present invention further disclose an optical module. According to the foregoing technical solutions, Z-direction space is fully utilized, thereby reducing the width of an optical channel and planar space occupied by the optical module.