Optical Waveguide Groove Segmentation and Mirror Nesting
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Solution Overview
Problem
The existing optical waveguide devices have limited design flexibility due to the configuration of grooves that extend through the substrate, restricting the placement of optical elements and increasing light loss and reliability issues.
Innovation Solution
The optical waveguide design features physically separate grooves for each core layer with inclined surfaces and optical path changing mirrors formed on these surfaces, which are not in contact with the core layers, allowing for increased design freedom and reduced light loss by embedding the mirrors within clad layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single groove extends through the substrate to divide multiple core layers, then the manufacturing process is simplified, but the design flexibility of the optical waveguide is reduced
Solution Approach 1:
The single continuous groove is divided into multiple separate grooves, with each groove corresponding to a specific core layer. This segmentation allows independent design and optimization of optical path changing mirrors for each core layer, thereby improving design flexibility while maintaining manufacturing feasibility through systematic processing
2Ease of operation
If optical path changing mirrors are formed directly on core layers, then the optical path can be changed effectively, but light loss increases and reliability decreases due to contact with core layers
Solution Approach 1:
An inclined surface structure is introduced as an intermediary between the optical path changing mirror and the core layer. The mirror is formed on the inclined surface that is part of the groove structure, not directly on the core layer. This intermediary structure allows effective optical path changing while preventing direct contact between the mirror and core layer, thereby reducing light loss and improving reliability
3Ease of manufacture
If optical path changing mirrors are exposed on the surface, then they are accessible for manufacturing, but they are vulnerable to dirt and damage
Solution Approach 1:
The optical path changing mirror is nested within the groove structure, specifically formed on the inclined surface that is surrounded by the groove walls. This nesting configuration provides protective coverage for the mirror, shielding it from external dirt and physical damage while maintaining manufacturing accessibility through the groove opening
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 enhances the design flexibility of optical waveguides, reduces light loss, and improves reliability by minimizing contact between the optical path changing mirrors and the core layers, while also protecting the mirrors from dirt and damage.
Implementation Method 1
grooves each provided corresponding to one of the core layers, with each groove including an inclined surface inclined a given angle with respect to an extension direction of the core layers
Data Source
AI summary
An optical waveguide includes a first clad layer, core layers each formed on the first clad layer, a second clad layer formed on the first clad layer to cover the core layers, grooves each provided corresponding to one of the core layers. The optical waveguide further includes inclined surfaces each disposed in the corresponding groove to face an end surface of the corresponding core layer in an extension direction of the core layers. Each inclined surface is inclined with respect to the extension direction of the core layers. The optical waveguide further includes optical path changing mirrors each formed on the corresponding inclined surface. The grooves are physically separate from each other. Each inclined surface is formed in only the first and second clad layers. Each optical path changing mirror is not in contact with the core layers and is physically separate from the core layers.