Silicon Optical Package with 45-Degree Turning Mirror
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Solution Overview
Problem
Edge-emitting lasers with large divergent angles pose challenges in optical packaging, requiring compact designs with precise alignment of mirrors and lenses to minimize size and maximize efficiency, while existing solutions struggle with signal speed and feature definition due to complex trace formations.
Innovation Solution
The optical package design incorporates a sub-mount with an edge-emitting laser, a collimating ball lens, and a mirror, where the sub-mount is fabricated using anisotropically etched silicon wafers with angled sidewalls to allow for close placement of the laser to the mirror, and a lid with vertical sidewalls to reduce package size, improving signal speed and feature definition by shortening conductor lengths and using a collimating ball lens to relax tolerance between components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the turning mirror is located close to the edge-emitting laser to minimize the sizes of the mirror and subsequent lenses, then the package size is reduced, but the alignment precision between the mirror and laser becomes more difficult to achieve
Solution Approach 1:
The patent merges the turning mirror and collimating lens into a single integrated component called a turning collimator. This combination eliminates the need for separate alignment of the mirror and lens, as they are pre-aligned relative to each other during manufacturing. The turning collimator is positioned close to the laser emitter, achieving compact packaging while maintaining precise optical alignment through the integrated design.
2Adaptability or versatility
If complex trace formations are used in existing optical package designs, then connectivity is achieved, but signal speed and feature definition deteriorate
Solution Approach 1:
The patent extracts the electrical interconnects from the complex trace formation approach and replaces them with wire bonds. This eliminates the need for long, complex printed circuit board traces that limited signal speed. The wire bonds provide direct electrical connections between components, significantly improving signal speed while maintaining necessary connectivity between the laser emitter, detector, and control circuitry.
3Ease of operation
If the turning mirror is located close to the edge-emitting laser, then the divergent angle management is improved, but the tolerance requirements between components become more stringent
Solution Approach 1:
The patent combines the turning mirror and collimating lens into a single turning collimator component. This integration ensures that the mirror and lens are pre-aligned with precise tolerances during manufacturing, eliminating the need for field alignment. The turning collimator is designed with the mirror and lens positioned at optimal distances from each other, ensuring proper management of the laser's divergent angles while maintaining relaxed overall package tolerances.
Solution Approach 2:
The turning collimator acts as an intermediary component between the laser emitter and the optical fiber. It receives the divergent light from the laser, performs both turning and collimating functions, and delivers the collimated light to the fiber. This intermediary design simplifies the optical path and reduces the cumulative tolerance requirements compared to separate mirror and lens arrangements.
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 design results in a more compact optical package with improved signal speed and feature definition, allowing for efficient light redirection and convergence, addressing the challenges of large divergent angles and complex trace formations.
Implementation Method 1
a 45 degree turning mirror is used to turn the light perpendicular to the package
Implementation Method 2
a collimating ball lens mounted on the sub-mount adjacent to the edge-emitting laser
Data Source
AI summary
An optical package includes a sub-mount, an edge-emitting laser mounted on the sub-mount, a collimating ball lens mounted on the sub-mount adjacent to the edge-emitting laser, a mirror mounted on the sub-mount adjacent to the collimating ball lens. The sub-mount is made of a bottom wafer. A lid is bonded to the sub-mount to form the laser package. The lid is made of a middle wafer bonded to a top wafer. The middle wafer defines an opening that accommodates the edge-emitting laser, the collimating ball lens, and the mirror. The opening is defined by vertical sidewalls. The top wafer further includes a lens above the mirror.