Optical Waveguide Device with Cladding Opening
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Solution Overview
Problem
Optical waveguide devices face reliability issues due to deformation of the optical path conversion mirror caused by the light emitting or receiving portion of optical elements protruding downward, leading to misalignment and deterioration of optical coupling characteristics.
Innovation Solution
The optical waveguide device is designed with a second cladding layer having an opening above the optical path conversion mirror, allowing the optical element's protruding portion to be positioned inside the opening, preventing deformation and ensuring reliable mounting, and enabling easy filling of underfill resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the light emitting portion protrudes downward from the optical element, then the optical element can be mounted on the cladding layer, but the protruding portion pushes down the cladding layer and deforms the optical path conversion mirror, causing misalignment and deteriorating optical coupling characteristics
Solution Approach 1:
The patent extracts the problematic interaction between the protruding light emitting portion and the cladding layer by introducing an opening in the second cladding layer. This allows the protruding portion to extend into the opening without pushing down the cladding layer, thereby separating the mounting function from the deformation problem and maintaining optical coupling reliability.
2Ease of manufacture
If the optical element is mounted directly on the cladding layer, then mounting is simplified, but the optical path conversion mirror is likely to be deformed leading to misalignment
Solution Approach 1:
The opening in the second cladding layer acts as an intermediary structure that mediates between the protruding light emitting portion and the optical path conversion mirror. This allows the optical element to be mounted on the cladding layer while preventing direct contact and deformation of the mirror, thus maintaining manufacturing simplicity without sacrificing alignment precision.
3Reliability
If the cladding layer is made continuous to protect the optical path conversion mirror, then the mirror is protected from deformation, but the protruding light emitting portion cannot be properly positioned
Solution Approach 1:
The patent segments the second cladding layer by forming an opening in it. This segmentation allows the cladding layer to remain continuous in most areas for protection while creating a localized discontinuity (opening) that enables proper positioning of the protruding light emitting portion without compromising mirror protection.
Data Source
AI summary
An optical waveguide device includes a wiring board; an optical waveguide having a first cladding layer, a core layer and a second cladding layer formed in this order on the wiring board; an optical path conversion mirror formed in the core layer; and an optical element mounted on the second cladding layer, the optical element comprising a light emitting portion or a light receiving portion protruding from a lower side thereof. The second cladding layer has an opening formed above the optical path conversion mirror. The optical element is mounted on the second cladding layer so that at least one end thereof is positioned above the opening of the second cladding layer. The light emitting portion or light receiving portion of the optical element is arranged the opening of the second cladding layer.