Tapered Waveguide Integration for Alignment-Tolerant Laser Assembly
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Solution Overview
Problem
Current optical connection techniques for integrating dies are costly and time-consuming due to the need for precise alignment of optical features, which is not compatible with high-volume manufacturing processes.
Innovation Solution
The integration of waveguide configurations on laser devices that allow for alignment-tolerant assembly, enabling optical coupling with low optical loss even under lateral misalignment, using evanescent or butt-coupling configurations and tapered waveguides to route light between dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If active alignment techniques are used to precisely align optical features, then optical coupling efficiency is improved, but manufacturing cost and time increase
Solution Approach 1:
The patent applies preliminary action by pre-aligning the waveguide structures during the fabrication process before final assembly. The waveguides are formed with predetermined geometries and positions on the substrates, so that when substrates are assembled, the optical coupling is already optimized without requiring time-consuming active alignment during manufacturing. This enables high-volume production while maintaining coupling efficiency.
Solution Approach 2:
The patent employs parameter changes by modifying the waveguide geometry parameters, specifically using tapered waveguide structures where the width varies along the propagation direction. This geometric parameter change creates an expanding beam profile that increases the overlap area between coupled waveguides, making the system tolerant to misalignment and reducing the need for precise active alignment during assembly.
2Reliability
If active alignment techniques are used to precisely align optical features, then optical coupling efficiency is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies preliminary action by pre-aligning the waveguide structures during the fabrication process before final assembly. The waveguides are formed with predetermined geometries and positions on the substrates, so that when substrates are assembled, the optical coupling is already optimized without requiring time-consuming active alignment during manufacturing. This enables high-volume production while maintaining coupling efficiency.
Solution Approach 2:
The patent employs parameter changes by modifying the waveguide geometry parameters, specifically using tapered waveguide structures where the width varies along the propagation direction. This geometric parameter change creates an expanding beam profile that increases the overlap area between coupled waveguides, making the system tolerant to misalignment and reducing the need for precise active alignment during assembly.
3Manufacturing precision
If conventional optical coupling is used, then alignment precision is improved, but misalignment tolerance decreases
Solution Approach 1:
The patent employs parameter changes by modifying the waveguide geometry parameters, specifically using tapered waveguide structures where the width varies along the propagation direction. This geometric parameter change creates an expanding beam profile that increases the overlap area between coupled waveguides, making the system tolerant to misalignment and reducing the need for precise active alignment during assembly.
Solution Approach 2:
The patent applies another dimension by transitioning from a simple butt-coupling geometry to a tapered geometry that utilizes the longitudinal dimension of the waveguide. The gradual change in width along the propagation direction provides an additional degree of freedom for optimizing coupling, allowing the system to accommodate lateral misalignments while maintaining efficient optical coupling.
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 reduces the cost and time required for alignment while maintaining low optical loss, allowing for efficient optical signal routing with misalignment tolerances of up to 5 microns or less, making it suitable for high-volume manufacturing.
Implementation Method 1
waveguide configurations on laser devices that allow for alignment-tolerant assembly, enabling optical coupling with low optical loss even under lateral misalignment, using evanescent or butt-coupling configurations
Implementation Method 2
waveguide configurations on laser devices that allow for alignment-tolerant assembly, enabling optical coupling with low optical loss even under lateral misalignment, using evanescent or butt-coupling configurations
Data Source
AI summary
Embodiments of the present disclosure provide optical connection techniques and configurations. In one embodiment, an apparatus includes a substrate, a laser device formed on the substrate, the laser device including an active layer configured to emit light, and a mode-expander waveguide disposed on the substrate and butt-coupled with the active layer to receive and route the light to a waveguide formed on another substrate. Other embodiments may be described and/or claimed.