Stamped Optical Bench Micro Mirrors Mux Demux
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Solution Overview
Problem
Existing optical multiplexers and demultiplexers face challenges in manufacturing complexity, high production costs, and reduced yield due to the need for precise optical alignment of multiple components, which is critical for single-mode optical communications, and are often bulky and costly.
Innovation Solution
A stamped optical bench with integrally formed alignment features and micro mirrors is used to route and redirect optical signals, allowing for passive alignment of optical components and reducing the number of components that require active alignment, thereby improving manufacturability, throughput, and reliability while minimizing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional multiple discrete optical components are used for multiplexing/demultiplexing, then optical signal routing functionality is achieved, but manufacturing complexity and production costs increase due to the need for precise active alignment
Solution Approach 1:
The patent combines multiple discrete optical components (lens array, mirrors, filters) into a single integrated optical bench structure. The optical bench includes a substrate with arrayed waveguides, grating couplers, and other photonic components fabricated as one unified device, eliminating the need for separate alignment of individual components and thereby reducing manufacturing complexity while maintaining optical precision
Solution Approach 2:
The patent replaces mechanical alignment systems with photolithographically defined optical paths. Instead of using mechanically adjustable mounts and mirrors requiring active alignment, the optical routes are precisely defined during semiconductor fabrication through photolithography, substituting mechanical adjustment with precision manufacturing processes
2Productivity
If multiple discrete optical components are used, then optical signal routing is achieved, but production yield decreases due to alignment difficulties
Solution Approach 1:
By integrating all optical components onto a single optical bench substrate, the patent eliminates the multi-step assembly process required for discrete components. The unified structure is fabricated in one semiconductor manufacturing cycle, dramatically improving production yield by removing alignment-related failure modes that plague multi-component assemblies
Solution Approach 2:
The patent changes the manufacturing approach from mechanical assembly with adjustable parameters to photolithographic fabrication with fixed parameters. The optical paths are defined by precise lithographic patterns rather than mechanical adjustments, transforming the manufacturing process into a high-yield semiconductor fabrication process
3Volume of moving object
If traditional multiplexer designs are used, then wavelength division multiplexing functionality is achieved, but device size becomes bulky
Solution Approach 1:
The patent implements a compact optical bench where components are nested within a small footprint. The arrayed waveguides are closely spaced and vertically integrated, with grating couplers and filters positioned in nested configurations that maximize space utilization, enabling WDM functionality in a miniaturized form factor suitable for modern optical modules
Solution Approach 2:
The patent transitions from planar two-dimensional component layouts to three-dimensional vertical integration. Optical paths are routed through multiple layers and depths within the optical bench, utilizing the vertical dimension to reduce the horizontal footprint and achieve compact WDM functionality
4Ease of manufacture
If thin-film filters and discrete mirrors are used, then wavelength-based optical signal splitting is achieved, but manufacturing cost increases
Solution Approach 1:
The patent replaces discrete thin-film filters and mirrors with photolithographically defined grating couplers and integrated waveguide filters. These components are fabricated using standard semiconductor processes, eliminating the need for separate, costly thin-film deposition and mirror assembly steps while maintaining reliable optical signal splitting through precisely controlled photonic structures
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 enables the creation of compact, cost-effective multiplexers and demultiplexers with improved alignment precision and reduced production costs, enhancing the reliability and ease of use of optical signal routing while maintaining the desired optical path accuracy.
Implementation Method 1
The optical bench includes an array of stamped reflective surfaces for routing/redirecting optical signals
Data Source
AI summary
A Mux/Demux subassembly includes a stamped optical bench, which includes an array of stamped reflective surfaces for redirecting optical signals. Alignment features and components of the Mux/Demux subassembly are integrally formed on a stamped optical bench, defining a desired optical path with optical alignment at tight tolerances. The optical bench is formed by stamping a malleable stock material (e.g., a metal stock), to form precise geometries and features of the optical bench.