Optical Waveguide End-Face Structure for Stronger Module Bonding
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Solution Overview
Problem
Existing optical modules face reduced bonding strength between the fiber block and PLC chip due to decreased bonding area when downsized, particularly in multi-core configurations, leading to potential reliability issues.
Innovation Solution
Incorporating separation grooves on both sides of the optical waveguide end faces with the inner grooves in a mirror-polished state and outer grooves having unevenness to increase bonding area and strength, using a manufacturing process that includes polishing, masking, and aligning optical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the optical module is downsized, then the device size is reduced, but the bonding area between fiber block and PLC chip decreases leading to reduced bonding strength
Solution Approach 1:
The invention applies different surface finish qualities to different regions of the end face. The inner portion (where light propagates) is mirror-polished for optical quality, while the outer portion (for bonding) is intentionally made rough/uneven to increase bonding area and strength. This local differentiation allows the module to be downsized while maintaining bonding strength through enhanced local bonding surface quality.
2Manufacturing precision
If the entire end face is mirror-polished, then optical quality is improved, but bonding strength is reduced due to smooth surface
Solution Approach 1:
The invention divides the end face into two functional zones with different surface characteristics: the inner portion is mirror-polished for optimal optical performance, while the outer portion is made rough or uneven to maximize bonding area and adhesive penetration, thereby achieving both high optical quality and strong bonding simultaneously.
Solution Approach 2:
The end face is segmented into an inner portion and an outer portion, each with distinct surface finish requirements. The separation groove visually and physically demarcates these regions, allowing independent optimization of surface treatment for each zone's specific function.
3Object-generated harmful factors
If separation grooves are added to prevent adhesive flow, then adhesive containment is improved, but device complexity increases
Solution Approach 1:
The separation groove divides the end face into inner and outer portions, creating a clear boundary that prevents adhesive from flowing into the optical path area. This simple geometric segmentation effectively contains adhesive to the bonding region without requiring complex sealing mechanisms.
Solution Approach 2:
The separation groove acts as an intermediary barrier between the bonding region and the optical transmission region. It mediates the interaction between adhesive and the inner portion, preventing harmful adhesive flow while maintaining a clean separation between functional zones.
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
Enhances the bonding strength between optical components, allowing for a more robust connection while enabling module downsizing without compromising reliability.
Implementation Method 1
the inner end face of the separation groove in the horizontal direction is in a mirror surface state... a region where a waveguide is formed inside the separation groove and light propagates
Data Source
AI summary
An optical component includes an optical waveguide, a separation groove disposed on both sides of the optical waveguide in an end face of the optical component connected to face an end face of another optical component, wherein the end face inside the separation groove is in a mirror surface state, and at least a part of the end face outside the separation groove has unevenness.