Redundant Optical Device Array for High Reliability
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Solution Overview
Problem
The existing arrays of optical devices, such as laser diodes and photodetectors, face challenges in reliability and cost due to limited materials and the inability to easily repair individual defective components within the array, leading to a low mean time between failures (MTBF) and high production costs.
Innovation Solution
The implementation of redundant optical devices in an array configuration, where multiple devices are grown on a wafer, processed, and connected to a control circuit, allowing for individual selection and substitution of active devices, enabling continuous operation even if one device fails, with the use of grouping trenches for isolation and common connections for signal sharing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If redundant optical devices are included in the array, then array reliability is improved, but manufacturing cost increases
Solution Approach 1:
Each optical device in the array is designed with universal functionality to perform the same optical task. Multiple lasers can all emit light for transmission, and multiple photodetectors can all detect optical signals. This universality allows any device in the array to replace any other device, eliminating the need for specialized backup components and reducing overall manufacturing costs while maintaining reliability.
Solution Approach 2:
The invention uses identical copies of optical devices (lasers or photodetectors) arranged in an array, where each copy is a functional duplicate of the others. These copied devices are manufactured using the same processes and materials, reducing the cost of creating redundant components. The control circuitry selectively activates appropriate copies based on operational needs, providing reliability without requiring expensive specialized backup components.
2Ease of manufacture
If optical devices are fabricated using standard epitaxial growth techniques, then manufacturing process is simplified, but device yield and defect rate are limited by material quality
Solution Approach 1:
The invention performs preliminary testing and characterization of each optical device individually before integrating it into the final array configuration. During this preliminary stage, devices are tested for defects and performance parameters. Based on these preliminary results, the control circuitry is configured to selectively activate only the defect-free or high-performance devices, thereby ensuring high yield and reliability in the final array without requiring more complex fabrication processes.
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 approach enhances the yield and reliability of optical device arrays by allowing for selective activation of redundant devices, reducing production costs and enabling easy repair, while maintaining operational performance and flexibility.
Implementation Method 1
Typically diode lasers or photodetectors are fabricated by growing the devices on a semiconductor substrate. Depending upon the particular devices and there design, this may entail the use of known techniques such as liquid-phase epitaxy, metal-organic vapor-phase epitaxy, molecular beam epitaxy.
Implementation Method 2
During these processes dielectric films and various metals are deposited on the semiconductor, for example, to isolate parts or create contacts.
Data Source
AI summary
An optical module has multiple optical devices. At least two of the multiple optical devices are a group. Each of the optical devices in the group are individually selectable relative to the others. The optical module also has a controller, coupled to the devices such that the controller can select which of the devices in the group will be active at a given time. A communications network has a first transmitter having a number of usable channels, a first receiver, and optical fibers connecting the first transmitter to the first receiver. The first transmitter has multiple lasers, at least some being selectable as either active or backup lasers. The multiple lasers are controllable such that, if a specific channel is in use by an active laser and a laser failure occurs for that channel, a redundant laser can be substituted for the active laser and, after the substitution, the specific channel can be used using the redundant laser.