Optical Waveguide Device Cladding Layer Adhesion

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Solution Overview

Problem

Conventional optical waveguide devices face issues with foreign material mixing between the core layer of the polymer waveguide and the silicon waveguide, which affects optical coupling and transmission efficiency.

Innovation Solution

The optical waveguide device incorporates a substrate with a first and second cladding layer, and a core layer, where the silicon waveguide is optically coupled to the core layer using a second cladding layer that acts as an adhesive, preventing foreign material mixing by being fixed to the substrate with the first cladding layer in between, and allowing for precise alignment and reduced optical loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the core layer of the polymer waveguide and the core layer of the silicon waveguide are placed in direct contact for optical coupling, then the optical coupling efficiency is improved, but foreign material mixing occurs between the two core layers

Engineering Contradiction:

Improveoptical coupling efficiencyVSAvoidforeign material mixing

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a first cladding layer as an intermediary between the substrate and the first core layer, and a second cladding layer as an intermediary between the first core layer and the second core layer. These cladding layers act as barrier structures that prevent foreign material mixing while maintaining optical coupling functionality, resolving the contradiction between coupling efficiency and contamination prevention.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent segments the waveguide structure into distinct layers (substrate, first cladding layer, first core layer, second cladding layer, second core layer) with clear interfaces. This segmentation creates physical barriers that prevent foreign material mixing between core layers while maintaining the optical coupling function through controlled interfaces.

Inventive Principle:

Principle #1Segmentation

2Object-affected harmful factors

If a multi-layer cladding structure is introduced to prevent foreign material mixing, then foreign material contamination is reduced, but the device structure becomes more complex

Engineering Contradiction:

Improveforeign material mixingVSAvoidwaveguide structure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The cladding layers serve multiple functions simultaneously: they act as optical confinement structures for the waveguide, serve as adhesive layers for mounting the optical semiconductor element, and function as barrier layers to prevent foreign material mixing. This multi-functionality reduces the need for additional separate structures, thereby limiting the increase in device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines the adhesive function with the cladding layer structure, eliminating the need for separate adhesive layers. The second cladding layer serves both as an optical component and as the adhesive that fixes the optical semiconductor element to the substrate, simplifying the overall structure compared to having separate adhesive and cladding layers.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If the optical semiconductor element is fixed using a separate adhesive layer, then the mounting reliability is improved, but foreign material may be introduced during the adhesive application process

Engineering Contradiction:

Improvemounting reliabilityVSAvoidforeign material mixing

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The second cladding layer is designed to serve dual purposes: as an optical confinement structure and as the adhesive layer for mounting. This eliminates the need for separate adhesive application processes that could introduce foreign materials, while maintaining mounting reliability through the adhesive properties of the cladding layer material.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 configuration effectively prevents foreign material mixing, enhances manufacturing throughput, and ensures reliable optical coupling with reduced optical loss, improving the overall performance and reliability of the optical waveguide device.

Implementation Method 1

the optical semiconductor element is fixed to the substrate by the second cladding layer

Methodology Applied

Scientific EffectAdhesive: Adhesive

Implementation Method 2

a second core layer optically coupled to the first core layer

Methodology Applied

Scientific EffectOptical coupling: Waveguide (optics)

Data Source

PatentUS20240385365A1Optical waveguide device

Publication Date: 2024.11.21 SHINKO ELECTRIC IND CO LTD

AI summary

An optical waveguide device includes an optical waveguide substrate, and an optical semiconductor element including a silicon waveguide and mounted on the optical waveguide substrate. The optical waveguide substrate includes a substrate, a first cladding layer formed on the substrate, a first core layer formed on the first cladding layer, and a second cladding layer formed on the first cladding layer and the first core layer. The silicon waveguide includes a second core layer optically coupled to the first core layer, and the optical semiconductor element is fixed to the substrate by the second cladding layer.