Two-Dimensional Actuator Beams for PIC Waveguide Alignment

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Solution Overview

Problem

Conventional edge optical coupling methods in photonic integrated circuits result in frequent misalignment of waveguides due to thermal expansion and manufacturing tolerances, leading to high insertion loss and yield issues, especially when using Silicon on Insulator (SOI) processes.

Innovation Solution

Implementing two-dimensional cantilevered actuator beams with piezoelectric actuators on photonic integrated circuits, allowing independent vertical and horizontal displacement to align waveguides, compensating for substrate warpage and manufacturing errors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional edge optical coupling methods are used to permanently attach optical fiber arrays to V-groove arrays, then the structural alignment is fixed, but misalignment occurs due to thermal expansion and manufacturing tolerances leading to high insertion loss

Engineering Contradiction:

Improvealignment stabilityVSAvoidwaveguide alignment precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent introduces dynamically adjustable actuator beams that can move waveguides in two dimensions (x and y directions) to compensate for misalignment. Instead of a fixed permanent attachment, the system uses controllable actuators to dynamically adjust waveguide positions, resolving the contradiction between fixed structural alignment and thermal/expansion-induced misalignment.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes the physical state of the mounting structure from rigid and fixed to adjustable and controllable. By implementing actuator beams with controlled displacement capabilities, the system can modify waveguide positions in response to thermal expansion and manufacturing variations, thereby maintaining alignment precision despite environmental changes.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If permanent attachment methods are used for optical fiber arrays, then assembly is simplified, but adjustment capability is lost resulting in high insertion loss due to misalignment

Engineering Contradiction:

Improveassembly simplicityVSAvoidoptical coupling efficiency

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces static permanent attachment with dynamic adjustable mounting using actuator beams. These beams allow the waveguides to be positioned and adjusted after assembly, maintaining both manufacturing simplicity and optical coupling efficiency by enabling post-assembly alignment corrections.

Inventive Principle:

Principle #15Dynamics

3Device complexity

If traditional alignment methods are used without adjustment capability, then device complexity is reduced, but yield decreases due to frequent misalignment issues

Engineering Contradiction:

Improvealignment system complexityVSAvoidpackaging yield

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent introduces a controlled level of complexity through actuator beams that enable dynamic alignment adjustment. This additional complexity directly addresses misalignment issues, thereby improving packaging yield by allowing correction of alignment errors that would otherwise result in defective assemblies.

Inventive Principle:

Principle #15Dynamics

4Stability of the object's composition

If rigid mounting structures are used for waveguides, then structural stability is maintained, but adaptability to different fiber pitches and optical components is reduced

Engineering Contradiction:

Improvestructural stabilityVSAvoidadaptability to fiber pitches

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent replaces rigid mounting structures with dynamic actuator beams that can adjust waveguide positions. This enables the system to adapt to different fiber pitches and optical component variations while maintaining structural stability through controlled positioning, thereby resolving the contradiction between rigidity and adaptability.

Inventive Principle:

Principle #15Dynamics

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

Achieves high-yield, high-throughput optical packaging with precise alignment of waveguides, adaptable to various fiber pitches and optical components, reducing misalignment and insertion loss.

Implementation Method 1

two-dimensional cantilevered actuator beams with piezoelectric actuators on photonic integrated circuits, allowing independent vertical and horizontal displacement

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Data Source

PatentUS20250298188A1Two-dimensional actuator beam for adjustable optical coupling on photonic integrated circuit structures

Publication Date: 2025.09.25 ALTERA CORP

AI summary

An apparatus comprises an integrated circuit (IC) package substrate, a photonic integrated circuit (PIC) die over or under the IC package substrate and comprising a first waveguide, and an optical component adjacent the PIC die and comprising an optical path. A beam cantilevered from a surface of the PIC die or the optical component has a second waveguide between the first waveguide and the optical path. The beam comprises a first plate portion extending in a horizontal or vertical plane, and a second plate portion distal from the first plate portion along a length of the beam and extending transversely to the first plate portion. The second waveguide extends along both the first and second plate portions.