Silicon Optical Bench Component Tilt Control
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Solution Overview
Problem
The fabrication and assembly of optical systems in trenches within silicon substrates face challenges due to oversized trenches and non-vertical side walls, leading to tilted optical components that divert optical energy out of the desired path, reducing signal quality and introducing unwanted energy into other systems.
Innovation Solution
Non-rectangular optical components with protruding arms are designed to be vertically aligned within the trenches, using resting features and functional coatings to ensure proper alignment and function, even with non-vertical side walls, thereby minimizing tilt errors and maintaining optical beam alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If oversized trenches are used to enable insertion of optical components, then ease of assembly is improved, but manufacturing precision deteriorates because components become tilted in the trenches
Solution Approach 1:
The optical component is segmented into a functional body and protruding arms. The arms extend laterally beyond the functional body and are designed to engage with the trench walls, while the functional body contains the optical functionality. This segmentation allows the component to be inserted into oversized trenches while the arms provide mechanical constraint to prevent tilting.
Solution Approach 2:
The solution transitions from a two-dimensional planar component to a three-dimensional structure with protruding arms that extend in lateral dimensions. These arms engage with the trench walls at different positions, creating a mechanical constraint system that prevents rotation and tilting of the component within the trench, thereby maintaining vertical alignment despite the oversized trench dimensions.
2Ease of manufacture
If conventional rectangular components are used in trenches with non-vertical side walls, then manufacturing simplicity is improved, but optical performance deteriorates due to component tilting and misalignment
Solution Approach 1:
The optical component incorporates asymmetric protruding arms that are specifically shaped to match the non-vertical side wall profile of the trenches. The arms have different geometries on opposite sides, allowing them to engage with the sloped or re-entrant trench walls. This asymmetric design compensates for the non-vertical trench walls, ensuring the functional body remains vertically aligned and properly oriented for optimal optical performance.
3Ease of operation
If optical components are tilted in trenches, then insertion into oversized trenches becomes easier, but energy efficiency deteriorates due to optical energy diversion out of the desired path
Solution Approach 1:
The protruding arms are pre-configured in specific orientations and positions during component fabrication. When the component is inserted into the trench, these pre-positioned arms automatically engage with the trench walls at predetermined locations, preemptively preventing any tilting or rotation. This preliminary mechanical constraint ensures the functional body maintains its correct vertical orientation, keeping optical beams properly aligned and preventing energy diversion.
Data Source
Figure 1A
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Figure 2
AI summary
An optical component (100) is provided. The optical component includes an optical-path portion (110) including an arm-connecting portion (112) and a lower portion (111), a first arm (141) extending from a first end (121) of the arm-connecting portion, and a second arm (142) extending from a second end of the arm-connecting portion. The first arm has at least one resting feature (151) and the second arm has at least one resting feature (152). The optical-path portion has an input surface (120). When the resting features of the first arm and the second arm are positioned on a top surface (158) at short edges (521) of a trench (501) in a trench system (500), the optical-path portion is vertically aligned in the trench.