Polymeric Vertical Waveguide Lens for VCSEL Coupling

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Solution Overview

Problem

Glass optical fibers are inconvenient for complex high-density circuitry due to their high cost, poor durability, and high fabrication costs, necessitating the development of cost-effective, reliable polymeric materials for integrated optical and optoelectronic devices.

Innovation Solution

A light coupling device with a vertical waveguide formed directly on a vertical-cavity surface-emitting laser (VCSEL) using polymeric materials, where the waveguide is formed by dispensing a high-viscosity waveguide material and capped with a refractive index matching layer to improve coupling efficiency and reduce alignment complexities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If glass optical fibers are used for high-speed data transfer, then transmission speed and data capacity are improved, but cost, durability, and ease of fabrication for complex photonic circuits deteriorate

Engineering Contradiction:

Improvetransmission speedVSAvoidfabrication cost and complexity

Core Design Contradiction:

SpeedVSEase of manufacture

Solution Approach 1:

The patent changes the material parameter from glass to polymer, creating polymeric optical fibers and waveguides that maintain optical transmission capabilities while enabling cost-effective fabrication through standard semiconductor processing techniques, thereby resolving the contradiction between transmission performance and manufacturing ease

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite polymeric structures including core-clad waveguide configurations and integrated lens assemblies that combine multiple functional materials to achieve both high-speed optical transmission and compatibility with semiconductor manufacturing processes

Inventive Principle:

Principle #40Composite materials

2Speed

If glass optical fibers are used, then high-speed data transfer is achieved, but durability and cost effectiveness worsen

Engineering Contradiction:

Improvedata transfer speedVSAvoiddurability

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The patent transitions from glass to polymer materials, changing the physical and chemical parameters to achieve improved flexibility, impact resistance, and overall durability while maintaining the high-speed data transfer capability through optimized polymeric waveguide designs

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If separate alignment with ball lens is used, then light coupling is achieved, but device complexity and alignment precision requirements increase

Engineering Contradiction:

Improvecoupling efficiencyVSAvoidalignment complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges the lens function directly into the waveguide structure by forming a lens at the distal end of the waveguide, eliminating the need for separate ball lens components and their associated alignment mechanisms, thereby reducing device complexity while maintaining coupling efficiency

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated lens acts as an intermediary element that is monolithically formed with the waveguide, serving as a built-in coupling interface that eliminates the need for external alignment components and simplifies the overall device architecture

Inventive Principle:

Principle #24Intermediary (Mediator)

4Ease of manufacture

If traditional fiber coupling methods are used, then light transmission is achieved, but package size and fabrication cost increase

Engineering Contradiction:

Improvefabrication costVSAvoidpackage size

Core Design Contradiction:

Ease of manufactureVSVolume of stationary object

Solution Approach 1:

The patent combines multiple functions (waveguide, lens, and coupling interface) into a single integrated polymeric component, eliminating the need for separate fibers, lenses, and alignment mechanisms, thereby reducing package size and fabrication cost simultaneously

Inventive Principle:

Principle #5Merging (Combining)

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

The solution lowers the overall cost of forming the light coupling device and enhances light coupling efficiency by eliminating the need for separate alignment with a ball lens, while enabling wafer-level packaging and reducing package size.

Implementation Method 1

a vertical waveguide on a top surface of the optical device, the vertical waveguide having a first refractive index

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Implementation Method 2

a capping layer over the vertical waveguide, the capping layer configured to be a lens for the vertical waveguide and the capping layer having a second refractive index

Methodology Applied

Scientific EffectRefraction: Refraction

Data Source

PatentUS9478939B2Light coupling device and methods of forming same

Publication Date: 2016.10.25 TAIWAN SEMICONDUCTOR MANUFACTURING CO LTD

AI summary

An embodiment is a semiconductor device comprising an optical device over a first substrate, a vertical waveguide on a top surface of the optical device, the vertical waveguide having a first refractive index, and a capping layer over the vertical waveguide, the capping layer configured to be a lens for the vertical waveguide and the capping layer having a second refractive index.