Optical Wedge and Port for Perpendicular Light Signal Transfer
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Solution Overview
Problem
Inconsistent etching processes lead to non-uniform alignment openings in optical devices, causing inconsistent separation between devices and resulting in optical loss during light signal transfer.
Innovation Solution
The use of wedges in optical devices to direct light signals perpendicular to the device surface, reducing the impact of separation inconsistencies by maintaining a consistent angle of incidence on the reflecting surfaces, thereby minimizing optical loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If alignment openings are etched into devices for precise alignment, then alignment between devices is improved, but manufacturing precision deteriorates due to non-uniform etching processes causing inconsistent opening depths
Solution Approach 1:
The patent introduces alignment balls as intermediary elements that span across alignment openings in both devices. These balls serve as a mediator that compensates for the non-uniform depths of the etched alignment openings, allowing precise alignment to be achieved despite manufacturing variations in the openings themselves
Solution Approach 2:
The patent changes the alignment parameter from relying on the depth of etched openings to relying on the diameter and position of alignment balls. By shifting the critical dimension control to the balls (which can be manufactured with higher precision) rather than the etched openings, the system achieves better alignment precision despite etching process variations
2Loss of energy
If devices are positioned at specific separation for efficient light transfer, then optical loss is reduced, but system reliability deteriorates due to inconsistent separation caused by non-uniform alignment opening depths
Solution Approach 1:
The alignment balls serve as intermediary spacers that establish a consistent separation distance between devices. By using the balls as the reference for separation rather than the variable-depth alignment openings, the system achieves reliable and consistent device spacing that ensures efficient optical coupling
Solution Approach 2:
The patent incorporates the alignment balls as pre-positioned elements that cushion against the effects of etching non-uniformity. These balls are placed beforehand to establish the correct separation distance, compensating in advance for the inconsistent depths of the etched alignment openings
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 configuration reduces optical loss by stabilizing the angle of light signal incidence, making the system less susceptible to variations in device separation and improving the efficiency of light signal transfer between devices.
Implementation Method 1
The port is configured to change the direction of the light signals from the first direction to a second direction that is toward a location above the device or below the device
Implementation Method 2
The wedge is configured to receive the light signals from the port such that the light signals travel through the wedge and then exit the wedge traveling in a direction that is toward a location above or below the device and that is at an angle in a range of 88° to 92° relative to the device
Data Source
AI summary
An optical device includes a waveguide immobilized on a base. The device includes a port configured to receive light signals from the waveguide such that the light signals travel through the port. The light signals enter the port traveling in a first direction. The port is configured to change the direction of the light signals from the first direction to a second direction that is toward a location above the device or below the device. The device also includes a wedge configured to receive the light signals from the port such that the light signals travel through the wedge and then exit the wedge traveling in a direction that is at an angle in a range of 88° to 92° relative to the device and that is toward a location above or below the device.