Two-Layer Optical Waveguide Mirror Structure Design
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Solution Overview
Problem
The existing three-layer optical waveguide manufacturing process is lengthy and costly, leading to increased optical loss and potential crosstalk due to the unnecessary formation of mirror structures in cladding layers, which also results in longer distances between the mirror and light emitting/receiving planes.
Innovation Solution
A two-layer optical waveguide is developed with a core layer and a cladding layer, where the mirror structure is formed directly on the core layer, reducing the need for an additional cladding layer and shortening the manufacturing process, and the base plate is removed after forming the cladding layer to minimize optical loss and crosstalk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a three-layer structure with cladding layers on both surfaces is used, then the optical waveguide can be manufactured with a standardized process, but the manufacturing period becomes long and cost increases
Solution Approach 1:
The patent removes one cladding layer from the traditional three-layer structure, extracting only the essential cladding function from the first surface while eliminating the redundant second cladding layer. This reduces the manufacturing process from three lamination steps to two, directly improving productivity without compromising optical performance
Solution Approach 2:
Instead of laminating cladding layers first and then forming the mirror structure afterward, the patent inverts the sequence by forming the mirror structure directly on the core layer before laminating the single cladding layer. This eliminates the need to form mirror structures within cladding layers, reducing manufacturing complexity and cost
2Reliability
If the mirror structure is formed after laminating three layers, then the complete waveguide structure is established, but the mirror structure is unnecessarily formed in the cladding layer portion increasing cost
Solution Approach 1:
The mirror structure is formed preliminarily on the core layer before the cladding layer is laminated. This preliminary action ensures the mirror is positioned exactly where needed on the core layer without requiring subsequent complex patterning steps through the cladding layer, reducing manufacturing cost and complexity
Solution Approach 2:
The patent extracts the mirror structure formation from the cladding layer processing step and performs it separately on the core layer beforehand. This separation eliminates the unnecessary formation of mirror structures in the cladding layer portion, directly reducing manufacturing cost
3Ease of manufacture
If the mirror structure is formed in the cladding layer portion, then the manufacturing process is simplified, but light is reflected on unnecessary portions causing crosstalk
Solution Approach 1:
The mirror structure is formed with local precision only on the specific portions of the core layer where light reflection is actually needed for optical coupling. By controlling the mirror formation process to apply reflective material only in these localized areas, the patent prevents light reflection on unnecessary portions, thereby eliminating crosstalk noise while maintaining manufacturing simplicity
Solution Approach 2:
The core layer serves as an intermediary substrate that allows precise positioning and formation of the mirror structure before the cladding layer is added. This intermediary approach enables accurate control of mirror locations to prevent crosstalk, while the subsequent cladding layer provides structural completion
4Strength
If the cladding layer thickness is increased to ensure complete coverage, then the waveguide structure is more robust, but the distance between mirror and light emitting/receiving plane increases causing optical loss
Solution Approach 1:
The patent applies partial cladding coverage only where structurally necessary, rather than uniformly thick cladding across the entire waveguide. The cladding layer is strategically positioned to provide structural robustness at critical areas while minimizing the distance between the mirror structure and the light emitting/receiving plane, thereby reducing optical loss
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 manufacturing time and cost, improves optical characteristics by minimizing optical loss, and prevents unwanted crosstalk by ensuring the mirror structure is only formed in the necessary portion of the core layer.
Implementation Method 1
a mirror structure provided at a plurality of positions on the first surface of the core layer, each mirror structure directing a light signal which travels in the core layer, toward the second surface of the core layer
Data Source
AI summary
A two-layer optical waveguide includes a core layer having a first surface and a second surface opposite to the first surface, and a cladding layer laminated on the first surface of the core layer. The two-layer optical waveguide further includes a mirror structure provided at a plurality of positions on the first surface of the core layer, the mirror structure directing a light signal which travels in the core layer, toward the second surface of the core layer. Each mirror structure includes an inclined plane formed on the first surface of the core layer, and a metal film formed on the inclined plane.