Optical Waveguide Core Alignment via Inclined Mirrors
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Solution Overview
Problem
In optical waveguide devices, the stacking of optical waveguides with different light path lengths leads to increased optical coupling loss due to uneven light path distances, compromising the reliability of optical characteristics.
Innovation Solution
The method involves forming first and second light path core layers with different lengths on a common cladding layer, creating inclined surface grooves and metal light path conversion mirrors on these surfaces, and covering them with a second cladding layer, ensuring precise alignment and minimizing optical coupling loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If optical waveguides are stacked with different light path lengths, then multiple light paths can be integrated, but optical coupling loss increases due to uneven light path distances
Solution Approach 1:
The patent transitions from vertical stacking of waveguides to lateral arrangement on the same substrate surface. By forming first and second light path core layers side-by-side on the same cladding layer, the invention eliminates the vertical dimension that causes path length differences and coupling loss, while still providing multiple independent light paths for different optical devices.
Solution Approach 2:
The patent divides the optical waveguide into separate first and second light path core layers with distinct light path lengths, allowing each layer to be optimized independently for different optical devices. This segmentation enables flexible configuration of multiple light paths without requiring vertical stacking, thus avoiding the coupling loss problem.
2Manufacturing precision
If core layers with different light path lengths are formed on the same surface, then alignment precision improves, but manufacturing complexity increases
Solution Approach 1:
The patent forms the first light path core layer and its groove portion with inclined surface before forming the second light path core layer. This preliminary action allows precise alignment of the second core layer relative to the first, as the groove structure is already in place to define the exact position and orientation, thereby achieving high alignment precision while managing manufacturing complexity through sequential formation.
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 approach allows for the alignment of core layers with varying light path lengths on the same surface, reducing optical coupling loss and enhancing the reliability of optical characteristics in optical waveguide devices.
Implementation Method 1
forming partially a metal layer having light reflection property on the respective inclined surfaces of the first light path core layer and the second light path core layer to obtain a light path conversion mirror
Data Source
AI summary
A method of manufacturing an optical waveguide, includes forming a first light path core layer having a first light path length on a first cladding layer, forming a groove portion having an inclined surface in an end side of the first light path core layer, forming a second light path core layer having a second light path length which is longer than the first light path length, in a lateral area of the first light path core layer, forming a groove portion having an inclined surface, arranged to an outer side than the groove portion of the first light path core layer, in an end side of the second light path core layer, forming partially a metal layer on the respective inclined surfaces of the first and second light path core layer, and forming a second cladding layer covering the first and second light path core layer.