Polymer Waveguide Optical Splitter on Silicon Substrate
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Solution Overview
Problem
Conventional optical interconnect assemblies are complex and inefficient due to the need for external lens alignment and fiber coupling, leading to increased cost and energy loss.
Innovation Solution
An optical splitter module is developed with a silicon substrate featuring a trench and polymer waveguide, utilizing slanted reflectors for light guidance and splitting, and conductive lines for alignment, eliminating the need for external lenses and fiber ribbons, and allowing for improved optical coupling and reduced assembly time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If external lens alignment and fiber coupling are used in conventional optical interconnect assemblies, then optical coupling can be achieved, but the assembly process becomes complex and energy loss increases
Solution Approach 1:
The patent merges the optical coupling function directly into the silicon substrate by fabricating waveguides and coupling structures during semiconductor manufacturing. This eliminates the need for separate external lenses and fiber coupling assemblies, thereby reducing both energy loss and assembly complexity while maintaining optical coupling efficiency.
Solution Approach 2:
The patent replaces the mechanical alignment system (external lenses, fiber ribbons, and manual alignment procedures) with a planar photonic integrated circuit approach where optical paths are defined by fabricated waveguide structures on the silicon substrate. This substitution eliminates mechanical complexity and reduces alignment-related energy losses.
2Ease of manufacture
If external lens alignment and fiber ribbons are used in conventional optical assemblies, then optical coupling is achieved, but fabrication cost increases
Solution Approach 1:
The patent combines multiple optical components (waveguides, couplers, and substrate integration) into a single fabricated structure using standard semiconductor manufacturing processes. This merging eliminates the need for separate fiber ribbons and external lenses, reducing both fabrication cost and assembly complexity simultaneously.
Solution Approach 2:
The patent changes the manufacturing approach from mechanical assembly of discrete optical components to planar photonic integration using semiconductor fabrication. This parameter change enables mass production with lower costs and reduced complexity by leveraging established CMOS manufacturing capabilities.
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 solution simplifies the assembly process, reduces energy loss, and enhances data transmission rates up to 50 Gbps per channel by integrating optical devices directly on a silicon substrate, improving RF performance and reducing fabrication costs.
Implementation Method 1
a refractive index of the polymer cladding layer is lower than a refractive index of the polymer core layer such that total internal reflection occurs when light travels inside the polymer waveguides
Implementation Method 2
a first reflector formed on the first slanted side walls, a second reflector formed on the second slanted side wall, and a third reflector formed on the slanted front wall of the intrusion structure
Data Source
AI summary
The application discloses a polymer-based optical splitter on a silicon surface. A trench is formed on the silicon surface and a polymer waveguide having three 45 degree reflectors is patterned in the trench. The trench has two slanted side walls opposite to each other. Two reflectors of the polymer waveguide are arranged on the two slanted side walls. An intrusion structure with a slanted front wall is located in the middle of the waveguide and the third reflector is formed on the slanted front wall. The first reflector receives an optical input source, the second reflector is aligned to return light to the end optical receiver. The third reflector functions as a light splitter and is aligned to an intermediate optical receiver. Light splitting ratio is determined by the third reflector size relative to the waveguide cross section near the third reflector. A fabrication method is disclosed thereof.