Optical Waveguide Sheet With Periodic Tapered Core

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Solution Overview

Problem

Manufacturing optical waveguides with a two-dimensional taper shape is challenging due to high production costs and difficulties in achieving reduced loss, as existing methods require complex semiconductor processes and are limited to short lengths.

Innovation Solution

An optical waveguide sheet with a core having a periodic structure of maximum and minimum diameter portions alternately arranged with taper portions in between, surrounded by a cladding, allowing for efficient light transmission and emission, and a manufacturing method using a cylindrical transfer roll to form cores with an infinite length.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If a two-dimensional taper shape is used to reduce optical coupling loss, then optical transmission efficiency is improved, but manufacturing difficulty and cost increase significantly

Engineering Contradiction:
Improveoptical coupling lossVSAvoidmanufacturing difficulty
Core Design Contradiction:
Loss of energyVSEase of manufacture

Solution Approach 1:

The optical waveguide is divided into three distinct sections: a first end with a first core diameter, a second end with a second core diameter, and a middle section with a gradually changing core diameter. This segmentation allows each section to be optimized independently for its specific function while simplifying the overall manufacturing process compared to creating a complex two-dimensional taper in a single step.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The invention transitions from attempting to create a two-dimensional taper (changing both width and height simultaneously) to creating a one-dimensional taper (changing core diameter along the propagation direction). This dimensional simplification makes the manufacturing process feasible using conventional techniques while still achieving the desired optical coupling improvement.

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

2Manufacturing precision

If semiconductor steps are used to manufacture tapered optical waveguides, then manufacturing precision is improved, but production cost and device complexity increase

Engineering Contradiction:
Improvetaper shape precisionVSAvoidmanufacturing process complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention replaces expensive semiconductor manufacturing steps with a more economical drawing or extrusion process. While the semiconductor method would provide precise taper control, it requires clean rooms, specialized equipment, and multiple processing steps. The drawing method uses simpler, more cost-effective equipment to achieve sufficient precision for optical applications.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention replaces the complex photochemical and thermal processing steps of semiconductor manufacturing with a mechanical drawing or extrusion process. This substitution eliminates the need for photolithography, etching, and deposition steps, significantly reducing device complexity and production cost while maintaining adequate manufacturing precision.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If conventional manufacturing methods are used, then production cost is reduced, but the maximum length of optical waveguides is limited

Engineering Contradiction:
Improveproduction costVSAvoidoptical waveguide length
Core Design Contradiction:
Ease of manufactureVSLength of moving object

Solution Approach 1:

The drawing or extrusion process allows for continuous production of optical waveguides of arbitrary length. Unlike semiconductor methods that are limited by wafer size and require multiple stitching steps, the drawing method can produce a single continuous waveguide structure from start to finish, enabling lengths of 50 cm or more without increasing complexity or cost.

Inventive Principle:
Principle #20Continuity of useful action

Data Source

PatentUS10948654B2Optical waveguide sheet, optical transmission module, and manufacturing method for an optical waveguide sheet
Publication Date: 2021.03.16 SONY GROUP CORP
  • US10948654B2 patent drawing
  • US10948654B2 patent drawing
  • US10948654B2 patent drawing

AI summary

An optical waveguide sheet according to the present technology includes a core and a cladding. The core is extending in a first direction and including a maximum diameter portion in a plane parallel to a second direction orthogonal to the first direction and a third direction orthogonal to the second direction is maximum, a minimum diameter portion in the plane parallel to the second direction and the third direction is minimum, and a taper portion in which widths of the core in both directions of the second direction and the third direction gradually change in the first direction between the maximum diameter portion and the minimum diameter portion, the core being provided such that the maximum diameter portion and the minimum diameter portion are alternately arranged in the first direction with the taper portion therebetween. The cladding is provided around the core.