Optical Waveguide Laminate Structure with Refractive Index Control

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Solution Overview

Problem

Existing optical waveguide technologies face challenges in creating efficient laminate structures with distinct refractive index differences between base and surface layers, which are crucial for effective light propagation and waveguide formation.

Innovation Solution

The development of optical waveguide articles with a laminate structure comprising a base layer and a surface layer made from different glass compositions, where the refractive index difference between the two layers is maintained through ion-exchange treatments to form high and low refractive index regions, enabling efficient light propagation within the waveguide.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If ion-exchange treatment is applied to increase the refractive index of the exposed region, then the refractive index difference between base and surface layers is improved, but the manufacturing complexity increases due to masking and treatment requirements

Engineering Contradiction:

Improverefractive index controlVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The glass laminate structure is divided into distinct base layer and surface layer, each with different glass compositions optimized for their specific functions. The base layer uses a first glass composition with specific properties while the surface layer uses a second glass composition with different properties, allowing independent optimization of each layer's refractive index and other characteristics without requiring complex ion-exchange treatments on the entire structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the waveguide structure are assigned different refractive indices through the use of different glass compositions in the base and surface layers. This local differentiation of material properties enables precise control of light propagation paths and refractive index distributions without requiring complex processing treatments, as the refractive index differences are built into the material structure itself.

Inventive Principle:

Principle #3Local quality

2Reliability

If a laminate structure with distinct refractive indices is created, then light propagation efficiency is improved, but the ease of manufacture decreases due to multi-layer fusion requirements

Engineering Contradiction:

Improvelight propagation efficiencyVSAvoidmanufacturing ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The base layer and surface layer are fused together to form an integrated glass laminate structure that functions as a single unified component. This merging of layers during manufacturing allows the complex multi-layer structure to be produced as one piece, simplifying fabrication while maintaining the distinct refractive index properties of each layer for effective light propagation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The waveguide structure uses composite glass materials with different compositions in the base and surface layers. Each layer is formulated with specific glass compositions that provide the desired refractive indices and other properties, creating a composite structure that achieves superior light propagation efficiency while maintaining manufacturability through established glass processing techniques.

Inventive Principle:

Principle #40Composite materials

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 allows for the creation of optical waveguides with precise refractive index control, enhancing light propagation and waveguide performance by ensuring the high refractive index region is surrounded by lower refractive index materials, thus improving the waveguide's functionality and applicability in integrated optics.

Implementation Method 1

a base layer and a surface layer fused to the base layer

Methodology Applied

Scientific EffectFusion:

Implementation Method 2

subjecting the masked substrate to an ion-exchange treatment to increase the refractive index of the exposed region

Methodology Applied

Scientific EffectIon exchange: Ion Exchange

Data Source

PatentUS11307352B2Optical waveguide article with laminate structure and method for forming the same

Publication Date: 2022.04.19 CORNING INC

AI summary

An optical waveguide article includes a base layer formed from a first glass composition with a refractive index nbase and a surface layer fused to the base layer and formed from a second glass composition with a refractive index nsurface. A waveguide is disposed within the surface layer. nbase and nsurface satisfy the equation |nsurface−nbase|≥0.001. A method for forming an optical waveguide article includes forming a waveguide in a surface layer of a glass laminate structure including a base layer fused to the surface layer. The base layer is formed from a first glass composition with a refractive index nbase. The surface layer is formed from a second glass composition with a refractive index nsurface. nbase and nsurface satisfy the equation |nsurface−nbase|≥0.0001.