Optical Waveguide Groove Segmentation for Strength

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Solution Overview

Problem

Conventional optical waveguides with inclined groove surfaces suffer from mechanical weakness and reliability issues due to large groove volumes and the risk of foreign matter adherence, particularly when coated with adhesives that can seep into these grooves.

Innovation Solution

The method involves forming a first cladding layer, a core layer with groove portions having light path conversion inclined surfaces, and a second cladding layer with light path conversion holes on the inclined surfaces, reducing groove volume and using photolithography for precise hole formation, and a sealing layer to hermetically seal air layers without entering the holes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If groove portions are formed as release spaces extended elongately to intersect orthogonally with core layers, then light path conversion is achieved, but mechanical strength of the optical waveguide deteriorates due to large groove volume

Engineering Contradiction:

Improvelight path conversionVSAvoidmechanical strength

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The groove portion is divided into a first groove portion and a second groove portion separated by a partition wall. This segmentation reduces the overall groove volume while maintaining the light path conversion function, thereby improving mechanical strength while preserving optical functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The groove portions are configured to extend in the thickness direction of the core layer rather than horizontally across the waveguide. This dimensional change reduces the groove volume and improves mechanical strength while still achieving light path conversion through the inclined surfaces.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of operation

If groove portions are connected elongately, then light path conversion is achieved, but reliability deteriorates due to increased risk of foreign matter adherence

Engineering Contradiction:

Improvelight path conversionVSAvoidlong-term reliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The groove portions are separated by partition walls, creating isolated groove regions. This segmentation prevents foreign matter from adhering across multiple connected grooves, improving reliability while maintaining light path conversion capability through each isolated groove portion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The partition walls extract and separate the groove portions from each other, removing the continuous pathway that would allow foreign matter adherence. This extraction of the connecting structure between grooves improves reliability without compromising the light path conversion function.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of operation

If groove portions are present, then light path conversion is achieved, but adhesive application becomes complex due to risk of adhesive seeping into grooves

Engineering Contradiction:

Improvelight path conversionVSAvoidadhesive application

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The partition walls create isolated groove portions that are easier to control during adhesive application. The segmented structure prevents adhesive from seeping into multiple connected grooves, simplifying the manufacturing process while maintaining light path conversion functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The partition walls act as intermediaries that block adhesive from entering the groove portions. This intermediary structure protects the groove areas from adhesive contamination while still allowing light path conversion, thereby simplifying adhesive application.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enhances mechanical strength and reliability by minimizing groove volume, reducing foreign matter adherence, and ensuring precise light path conversion while preventing adhesive ingress into the holes, thus improving the long-term performance of optical waveguides.

Implementation Method 1

In the air boundary of the inclined surface in the groove portion, the light which is propagated through the core layer is made to reflect in the vertical direction, and the light path is converted.

Methodology Applied

Scientific EffectTotal internal reflection: Total Internal Reflection

Data Source

PatentUS8611715B2Optical waveguide and method of manufacturing the same, and optical waveguide device

Publication Date: 2013.12.17 SHINKO ELECTRIC IND CO LTD

AI summary

A method of manufacturing an optical waveguide, includes forming a first cladding layer on a substrate, forming a core layer on the first cladding layer, forming a groove portion including a light path conversion inclined surface by processing the core layer in a thickness direction, and forming a second cladding layer in which a light path conversion hole is arranged on the light path conversion inclined surface on the first cladding layer and the core layer.